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ABB A135-M66 manuals available for free PDF download: Operation Manual
ABB A135-M66 Operation Manual (152 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 19.1 MB
Table of Contents
Operation Manual / A130-M - A145-M
3
Table of Contents
3
Operation Manual / A130-M
6
Introduction
6
Purpose of the Manual
6
Fig. 1: Serial Number (01) on the Rating Plate
6
Contact Information
7
Essential Information
7
Layout and Function of the Turbocharger
8
Fig. 2: Layout and Function of the Turbocharger
8
Fig. 3: Compressor Wheel Cooling
9
Symbols, Definitions
10
Table 1: Definition of Pictograms
11
Storage of New Turbochargers and Spare Parts
12
Fig. 4: Volatile Corrosion Inhibitor (VCI)
12
Fig. 5: Package with Hygrometer
13
Registered Trademarks
14
Safety
15
Introduction
15
CE Conformity
15
Definition of Mandatory Signs
16
Definition of Safety Instructions
16
Table 2: Personal Protective Equipment to be Worn at All Times
16
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
16
Intended Use
17
Deflagration on Gas Engines
18
Warning Plates on the Turbocharger
19
Fig. 6: Warning Plate Locations
19
Turbocharger Rating Plate
20
Fig. 7: Rating Plate
20
Fig. 8: Locations of the Rating Plates
21
Periodic Check of the Pressure Vessels
22
Lifting of Loads
23
Fig. 9: Attachment of Loads on the Crane Hook
23
Fig. 10: Attachment Angle
23
Prerequisites for Operation and Maintenance
24
Hazards During Operation and Maintenance
25
Safe Operation
27
Fig. 11
27
Safe Maintenance
28
Removing and Installing
32
Turbocharger Weight and Transportation
32
Fig. 12: Suspension of Complete Turbocharger Unit
32
Table 4: Weight of Complete Turbocharger Unit
32
Fig. 13: Turbine Cleaning Nozzle
33
Removing the Turbocharger
33
Fig. 14: Removing the Turbocharger
34
Fig. 15: Loosening the Clamping Nut
36
Fig. 16: Turbocharger Centre of Gravity
37
Installing the Turbocharger
38
Fig. 17: Inserting Gaskets into the Bracket
38
Fig. 18: Fitting Threaded Rods Onto the Bracket
39
Fig. 19: Requirements for Threaded Rods
39
Table 5: Requirements for Threaded Rods
39
Fig. 20: Placing the Turbocharger on the Bracket
40
Table 6: Tightening Torque for Standard Nuts
41
Fig. 21: Preparing the Clamping Nut for the Tightening Procedure
42
Fig. 22: Tightening Pressure Screws
43
Table 7: Torque-Controlled Tightening of the Pressure Screws
43
Fig. 23: Connecting the Speed Sensor
44
Fig. 24: Connecting the Compressor Cooling Air Intake
44
Fig. 25: Attaching the Support
45
Commissioning
46
Oil Supply
46
Fig. 26: Oil Orifice
46
Inspection Procedures
48
Commissioning after Taking out of Operation
50
Monitoring Operation
51
Oil Pressure, Oil Temperature
51
Table 8: Lubricating Oil Pressure at Oil Inlet before Turbocharger
51
Table 9: Lubricating Oil Temperature at the Inlet
52
Table 10: Lubricating Oil Temperature at the Outlet
52
Exhaust Gas Temperature before Turbine
53
Fig. 27: Layout and Overview of Speed Measurement System
54
Turbocharger Speed
54
Fig. 28: Replacing the Speed Sensor
56
Table 11: Tightening Torque (86505)
56
Operation and Service
57
Noise Emission
57
Fig. 29: Noise Insulation, Bellows
58
Service Work
59
Fig. 30: Replacing the Protective Grid
61
Expected Replacement Intervals
63
Table 12: Expected Replacement Intervals
63
Stopping the Engine
65
Periodic Maintenance Work
66
Foreword to Maintenance
66
Table 13: Maintenance Table
66
Cleaning the Compressor During Operation
67
Fig. 31: Carrying out Wet Cleaning of Compressor
69
Table 14: Parameters for Wet Cleaning of Compressor
69
Cleaning the Turbine During Operation
70
Table 15: Turbine Wet Cleaning, Recommended Operating State
72
Fig. 32: Carrying out Wet Cleaning of Turbine
73
Table 16: Wet Cleaning of Turbine, Parameters
73
Cleaning Components Mechanically
74
Fig. 33: Cleaning the Filter Silencer
75
Fig. 34: Compressor-End, Non-Rotating Parts
77
Fig. 35: Turbine End, Non-Rotating Parts
78
Fig. 36: Soaking the Turbine End
81
Table 17: Value Table for Soaking
81
Table 20: Malfunctions When Starting - Rubbing of Rotating Parts
84
Table 19: Malfunctions When Starting - Vibrations
84
Table 18: Malfunctions When Starting - Delayed Start-Up
84
Malfunctions When Starting
84
Eliminating Malfunctions
84
Malfunctions During Operation
85
Table 21: Malfunctions During Operation - Lubricating Oil Pressure too Low
85
Table 22: Malfunctions During Operation - Speed Reduces
85
Table 23: Malfunctions During Operation - Speed Increases
85
Table 24: Malfunctions During Operation - Exhaust Gas Temperature too High
86
Table 25: Malfunctions During Operation - Charge Air Pressure too Low
86
Table 26: Malfunctions During Operation - Charge Air Pressure too High
87
Table 27: Malfunctions During Operation - Engine Performance Losses
87
Turbocharger Is Surging
88
Table 28: Malfunction - Turbocharger Surging
88
Table 29: Malfunction - Sporadic Surge Blows
88
Table 31: Malfunctions When Stopping - Runout Time too Short
89
Table 30: Malfunctions When Stopping - Runout Noises
89
Malfunctions When Stopping
89
Speed Measurement System
90
Table 32: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
90
Table 33: Malfunction of the Speed Measurement System - Measured Speed too High
90
Table 34: Malfunction of the Speed Measurement System - Measured Speed too Low
90
Dismantling and Fitting
91
Introduction
91
Material Required
92
Fig. 37: Swivel Lifting Eye (Example)
92
Table 35: Swivel Lifting Eyes
92
Fig. 38: Starpoint Ring Nut VRM
93
Advertisement
ABB A135-M66 Operation Manual (152 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 19.1 MB
Table of Contents
Operation Manual / A130-M - A145-M
3
Table of Contents
3
Operation Manual / A130-M
6
Introduction
6
Purpose of the Manual
6
Fig. 1: Serial Number (01) on the Rating Plate
6
Contact Information
7
Essential Information
7
Layout and Function of the Turbocharger
8
Fig. 2: Layout and Function of the Turbocharger
8
Fig. 3: Compressor Wheel Cooling
9
Symbols, Definitions
10
Table 1: Definition of Pictograms
11
Storage of New Turbochargers and Spare Parts
12
Fig. 4: Volatile Corrosion Inhibitor (VCI)
12
Fig. 5: Package with Hygrometer
13
Registered Trademarks
14
Safety
15
Introduction
15
CE Conformity
15
Definition of Mandatory Signs
16
Definition of Safety Instructions
16
Table 2: Personal Protective Equipment to be Worn at All Times
16
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
16
Intended Use
17
Deflagration on Gas Engines
18
Warning Plates on the Turbocharger
19
Fig. 6: Warning Plate Locations
19
Turbocharger Rating Plate
20
Fig. 7: Rating Plate
20
Fig. 8: Locations of the Rating Plates
21
Periodic Check of the Pressure Vessels
22
Lifting of Loads
23
Fig. 9: Attachment of Loads on the Crane Hook
23
Fig. 10: Attachment Angle
23
Prerequisites for Operation and Maintenance
24
Hazards During Operation and Maintenance
25
Safe Operation
27
Fig. 11
27
Safe Maintenance
28
Removing and Installing
32
Turbocharger Weight and Transportation
32
Fig. 12: Suspension of Complete Turbocharger Unit
32
Table 4: Weight of Complete Turbocharger Unit
32
Fig. 13: Turbine Cleaning Nozzle
33
Removing the Turbocharger
33
Fig. 14: Removing the Turbocharger
34
Fig. 15: Loosening the Clamping Nut
36
Fig. 16: Turbocharger Centre of Gravity
37
Installing the Turbocharger
38
Fig. 17: Inserting Gaskets into the Bracket
38
Fig. 18: Fitting Threaded Rods Onto the Bracket
39
Fig. 19: Requirements for Threaded Rods
39
Table 5: Requirements for Threaded Rods
39
Fig. 20: Placing the Turbocharger on the Bracket
40
Table 6: Tightening Torque for Standard Nuts
41
Fig. 21: Preparing the Clamping Nut for the Tightening Procedure
42
Fig. 22: Tightening Pressure Screws
43
Table 7: Torque-Controlled Tightening of the Pressure Screws
43
Fig. 23: Connecting the Speed Sensor
44
Fig. 24: Connecting the Compressor Cooling Air Intake
44
Fig. 25: Attaching the Support
45
Commissioning
46
Oil Supply
46
Fig. 26: Oil Orifice
46
Inspection Procedures
48
Commissioning after Taking out of Operation
50
Monitoring Operation
51
Oil Pressure, Oil Temperature
51
Table 8: Lubricating Oil Pressure at Oil Inlet before Turbocharger
51
Table 9: Lubricating Oil Temperature at the Inlet
52
Table 10: Lubricating Oil Temperature at the Outlet
52
Exhaust Gas Temperature before Turbine
53
Fig. 27: Layout and Overview of Speed Measurement System
54
Turbocharger Speed
54
Fig. 28: Replacing the Speed Sensor
56
Table 11: Tightening Torque (86505)
56
Operation and Service
57
Noise Emission
57
Fig. 29: Noise Insulation, Bellows
58
Service Work
59
Fig. 30: Replacing the Protective Grid
61
Expected Replacement Intervals
63
Table 12: Expected Replacement Intervals
63
Stopping the Engine
65
Periodic Maintenance Work
66
Foreword to Maintenance
66
Table 13: Maintenance Table
66
Cleaning the Compressor During Operation
67
Fig. 31: Carrying out Wet Cleaning of Compressor
69
Table 14: Parameters for Wet Cleaning of Compressor
69
Cleaning the Turbine During Operation
70
Table 15: Turbine Wet Cleaning, Recommended Operating State
72
Fig. 32: Carrying out Wet Cleaning of Turbine
73
Table 16: Wet Cleaning of Turbine, Parameters
73
Cleaning Components Mechanically
74
Fig. 33: Cleaning the Filter Silencer
75
Fig. 34: Compressor-End, Non-Rotating Parts
77
Fig. 35: Turbine End, Non-Rotating Parts
78
Fig. 36: Soaking the Turbine End
81
Table 17: Value Table for Soaking
81
Table 20: Malfunctions When Starting - Rubbing of Rotating Parts
84
Table 19: Malfunctions When Starting - Vibrations
84
Table 18: Malfunctions When Starting - Delayed Start-Up
84
Malfunctions When Starting
84
Eliminating Malfunctions
84
Malfunctions During Operation
85
Table 21: Malfunctions During Operation - Lubricating Oil Pressure too Low
85
Table 22: Malfunctions During Operation - Speed Reduces
85
Table 23: Malfunctions During Operation - Speed Increases
85
Table 24: Malfunctions During Operation - Exhaust Gas Temperature too High
86
Table 25: Malfunctions During Operation - Charge Air Pressure too Low
86
Table 26: Malfunctions During Operation - Charge Air Pressure too High
87
Table 27: Malfunctions During Operation - Engine Performance Losses
87
Turbocharger Is Surging
88
Table 28: Malfunction - Turbocharger Surging
88
Table 29: Malfunction - Sporadic Surge Blows
88
Table 31: Malfunctions When Stopping - Runout Time too Short
89
Table 30: Malfunctions When Stopping - Runout Noises
89
Malfunctions When Stopping
89
Speed Measurement System
90
Table 32: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
90
Table 33: Malfunction of the Speed Measurement System - Measured Speed too High
90
Table 34: Malfunction of the Speed Measurement System - Measured Speed too Low
90
Dismantling and Fitting
91
Introduction
91
Material Required
92
Fig. 37: Swivel Lifting Eye (Example)
92
Table 35: Swivel Lifting Eyes
92
Fig. 38: Starpoint Ring Nut VRM
93
ABB A135-M66 Operation Manual (152 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 19.1 MB
Table of Contents
Operation Manual / A130-M - A145-M
3
Table of Contents
3
Operation Manual / A130-M
6
Introduction
6
Purpose of the Manual
6
Fig. 1: Serial Number (01) on the Rating Plate
6
Contact Information
7
Essential Information
7
Layout and Function of the Turbocharger
8
Fig. 2: Layout and Function of the Turbocharger
8
Fig. 3: Compressor Wheel Cooling
9
Symbols, Definitions
10
Table 1: Definition of Pictograms
11
Storage of New Turbochargers and Spare Parts
12
Fig. 4: Volatile Corrosion Inhibitor (VCI)
12
Fig. 5: Package with Hygrometer
13
Registered Trademarks
14
Safety
15
Introduction
15
CE Conformity
15
Definition of Mandatory Signs
16
Definition of Safety Instructions
16
Table 2: Personal Protective Equipment to be Worn at All Times
16
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
16
Intended Use
17
Deflagration on Gas Engines
18
Warning Plates on the Turbocharger
19
Fig. 6: Warning Plate Locations
19
Turbocharger Rating Plate
20
Fig. 7: Rating Plate
20
Fig. 8: Locations of the Rating Plates
21
Periodic Check of the Pressure Vessels
22
Lifting of Loads
23
Fig. 9: Attachment of Loads on the Crane Hook
23
Fig. 10: Attachment Angle
23
Prerequisites for Operation and Maintenance
24
Hazards During Operation and Maintenance
25
Safe Operation
27
Fig. 11
27
Safe Maintenance
28
Removing and Installing
32
Turbocharger Weight and Transportation
32
Fig. 12: Suspension of Complete Turbocharger Unit
32
Table 4: Weight of Complete Turbocharger Unit
32
Fig. 13: Turbine Cleaning Nozzle
33
Removing the Turbocharger
33
Fig. 14: Removing the Turbocharger
34
Fig. 15: Loosening the Clamping Nut
36
Fig. 16: Turbocharger Centre of Gravity
37
Installing the Turbocharger
38
Fig. 17: Inserting Gaskets into the Bracket
38
Fig. 18: Fitting Threaded Rods Onto the Bracket
39
Fig. 19: Requirements for Threaded Rods
39
Table 5: Requirements for Threaded Rods
39
Fig. 20: Placing the Turbocharger on the Bracket
40
Table 6: Tightening Torque for Standard Nuts
41
Fig. 21: Preparing the Clamping Nut for the Tightening Procedure
42
Fig. 22: Tightening Pressure Screws
43
Table 7: Torque-Controlled Tightening of the Pressure Screws
43
Fig. 23: Connecting the Speed Sensor
44
Fig. 24: Connecting the Compressor Cooling Air Intake
44
Fig. 25: Attaching the Support
45
Commissioning
46
Oil Supply
46
Fig. 26: Oil Orifice
46
Inspection Procedures
48
Commissioning after Taking out of Operation
50
Monitoring Operation
51
Oil Pressure, Oil Temperature
51
Table 8: Lubricating Oil Pressure at Oil Inlet before Turbocharger
51
Table 9: Lubricating Oil Temperature at the Inlet
52
Table 10: Lubricating Oil Temperature at the Outlet
52
Exhaust Gas Temperature before Turbine
53
Fig. 27: Layout and Overview of Speed Measurement System
54
Turbocharger Speed
54
Fig. 28: Replacing the Speed Sensor
56
Table 11: Tightening Torque (86505)
56
Operation and Service
57
Noise Emission
57
Fig. 29: Noise Insulation, Bellows
58
Service Work
59
Fig. 30: Replacing the Protective Grid
61
Expected Replacement Intervals
63
Table 12: Expected Replacement Intervals
63
Stopping the Engine
65
Periodic Maintenance Work
66
Foreword to Maintenance
66
Table 13: Maintenance Table
66
Cleaning the Compressor During Operation
67
Fig. 31: Carrying out Wet Cleaning of Compressor
69
Table 14: Parameters for Wet Cleaning of Compressor
69
Cleaning the Turbine During Operation
70
Table 15: Turbine Wet Cleaning, Recommended Operating State
72
Fig. 32: Carrying out Wet Cleaning of Turbine
73
Table 16: Wet Cleaning of Turbine, Parameters
73
Cleaning Components Mechanically
74
Fig. 33: Cleaning the Filter Silencer
75
Fig. 34: Compressor-End, Non-Rotating Parts
77
Fig. 35: Turbine End, Non-Rotating Parts
78
Fig. 36: Soaking the Turbine End
81
Table 17: Value Table for Soaking
81
Table 20: Malfunctions When Starting - Rubbing of Rotating Parts
84
Table 19: Malfunctions When Starting - Vibrations
84
Table 18: Malfunctions When Starting - Delayed Start-Up
84
Malfunctions When Starting
84
Eliminating Malfunctions
84
Malfunctions During Operation
85
Table 21: Malfunctions During Operation - Lubricating Oil Pressure too Low
85
Table 22: Malfunctions During Operation - Speed Reduces
85
Table 23: Malfunctions During Operation - Speed Increases
85
Table 24: Malfunctions During Operation - Exhaust Gas Temperature too High
86
Table 25: Malfunctions During Operation - Charge Air Pressure too Low
86
Table 26: Malfunctions During Operation - Charge Air Pressure too High
87
Table 27: Malfunctions During Operation - Engine Performance Losses
87
Turbocharger Is Surging
88
Table 28: Malfunction - Turbocharger Surging
88
Table 29: Malfunction - Sporadic Surge Blows
88
Table 31: Malfunctions When Stopping - Runout Time too Short
89
Table 30: Malfunctions When Stopping - Runout Noises
89
Malfunctions When Stopping
89
Speed Measurement System
90
Table 32: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
90
Table 33: Malfunction of the Speed Measurement System - Measured Speed too High
90
Table 34: Malfunction of the Speed Measurement System - Measured Speed too Low
90
Dismantling and Fitting
91
Introduction
91
Material Required
92
Fig. 37: Swivel Lifting Eye (Example)
92
Table 35: Swivel Lifting Eyes
92
Fig. 38: Starpoint Ring Nut VRM
93
Advertisement
ABB A135-M66 Operation Manual (152 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 19.1 MB
Table of Contents
Operation Manual / A130-M - A145-M
3
Table of Contents
3
Operation Manual / A130-M
6
Introduction
6
Purpose of the Manual
6
Fig. 1: Serial Number (01) on the Rating Plate
6
Contact Information
7
Essential Information
7
Layout and Function of the Turbocharger
8
Fig. 2: Layout and Function of the Turbocharger
8
Fig. 3: Compressor Wheel Cooling
9
Symbols, Definitions
10
Table 1: Definition of Pictograms
11
Storage of New Turbochargers and Spare Parts
12
Fig. 4: Volatile Corrosion Inhibitor (VCI)
12
Fig. 5: Package with Hygrometer
13
Registered Trademarks
14
Safety
15
Introduction
15
CE Conformity
15
Definition of Mandatory Signs
16
Definition of Safety Instructions
16
Table 2: Personal Protective Equipment to be Worn at All Times
16
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
16
Intended Use
17
Deflagration on Gas Engines
18
Warning Plates on the Turbocharger
19
Fig. 6: Warning Plate Locations
19
Turbocharger Rating Plate
20
Fig. 7: Rating Plate
20
Fig. 8: Locations of the Rating Plates
21
Periodic Check of the Pressure Vessels
22
Lifting of Loads
23
Fig. 9: Attachment of Loads on the Crane Hook
23
Fig. 10: Attachment Angle
23
Prerequisites for Operation and Maintenance
24
Hazards During Operation and Maintenance
25
Safe Operation
27
Fig. 11
27
Safe Maintenance
28
Removing and Installing
32
Turbocharger Weight and Transportation
32
Fig. 12: Suspension of Complete Turbocharger Unit
32
Table 4: Weight of Complete Turbocharger Unit
32
Fig. 13: Turbine Cleaning Nozzle
33
Removing the Turbocharger
33
Fig. 14: Removing the Turbocharger
34
Fig. 15: Loosening the Clamping Nut
36
Fig. 16: Turbocharger Centre of Gravity
37
Installing the Turbocharger
38
Fig. 17: Inserting Gaskets into the Bracket
38
Fig. 18: Fitting Threaded Rods Onto the Bracket
39
Fig. 19: Requirements for Threaded Rods
39
Table 5: Requirements for Threaded Rods
39
Fig. 20: Placing the Turbocharger on the Bracket
40
Table 6: Tightening Torque for Standard Nuts
41
Fig. 21: Preparing the Clamping Nut for the Tightening Procedure
42
Fig. 22: Tightening Pressure Screws
43
Table 7: Torque-Controlled Tightening of the Pressure Screws
43
Fig. 23: Connecting the Speed Sensor
44
Fig. 24: Connecting the Compressor Cooling Air Intake
44
Fig. 25: Attaching the Support
45
Commissioning
46
Oil Supply
46
Fig. 26: Oil Orifice
46
Inspection Procedures
48
Commissioning after Taking out of Operation
50
Monitoring Operation
51
Oil Pressure, Oil Temperature
51
Table 8: Lubricating Oil Pressure at Oil Inlet before Turbocharger
51
Table 9: Lubricating Oil Temperature at the Inlet
52
Table 10: Lubricating Oil Temperature at the Outlet
52
Exhaust Gas Temperature before Turbine
53
Fig. 27: Layout and Overview of Speed Measurement System
54
Turbocharger Speed
54
Fig. 28: Replacing the Speed Sensor
56
Table 11: Tightening Torque (86505)
56
Operation and Service
57
Noise Emission
57
Fig. 29: Noise Insulation, Bellows
58
Service Work
59
Fig. 30: Replacing the Protective Grid
61
Expected Replacement Intervals
63
Table 12: Expected Replacement Intervals
63
Stopping the Engine
65
Periodic Maintenance Work
66
Foreword to Maintenance
66
Table 13: Maintenance Table
66
Cleaning the Compressor During Operation
67
Fig. 31: Carrying out Wet Cleaning of Compressor
69
Table 14: Parameters for Wet Cleaning of Compressor
69
Cleaning the Turbine During Operation
70
Table 15: Turbine Wet Cleaning, Recommended Operating State
72
Fig. 32: Carrying out Wet Cleaning of Turbine
73
Table 16: Wet Cleaning of Turbine, Parameters
73
Cleaning Components Mechanically
74
Fig. 33: Cleaning the Filter Silencer
75
Fig. 34: Compressor-End, Non-Rotating Parts
77
Fig. 35: Turbine End, Non-Rotating Parts
78
Fig. 36: Soaking the Turbine End
81
Table 17: Value Table for Soaking
81
Table 20: Malfunctions When Starting - Rubbing of Rotating Parts
84
Table 19: Malfunctions When Starting - Vibrations
84
Table 18: Malfunctions When Starting - Delayed Start-Up
84
Malfunctions When Starting
84
Eliminating Malfunctions
84
Malfunctions During Operation
85
Table 21: Malfunctions During Operation - Lubricating Oil Pressure too Low
85
Table 22: Malfunctions During Operation - Speed Reduces
85
Table 23: Malfunctions During Operation - Speed Increases
85
Table 24: Malfunctions During Operation - Exhaust Gas Temperature too High
86
Table 25: Malfunctions During Operation - Charge Air Pressure too Low
86
Table 26: Malfunctions During Operation - Charge Air Pressure too High
87
Table 27: Malfunctions During Operation - Engine Performance Losses
87
Turbocharger Is Surging
88
Table 28: Malfunction - Turbocharger Surging
88
Table 29: Malfunction - Sporadic Surge Blows
88
Table 31: Malfunctions When Stopping - Runout Time too Short
89
Table 30: Malfunctions When Stopping - Runout Noises
89
Malfunctions When Stopping
89
Speed Measurement System
90
Table 32: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
90
Table 33: Malfunction of the Speed Measurement System - Measured Speed too High
90
Table 34: Malfunction of the Speed Measurement System - Measured Speed too Low
90
Dismantling and Fitting
91
Introduction
91
Material Required
92
Fig. 37: Swivel Lifting Eye (Example)
92
Table 35: Swivel Lifting Eyes
92
Fig. 38: Starpoint Ring Nut VRM
93
ABB A135-M66 Operation Manual (152 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 19.1 MB
Table of Contents
Operation Manual / A130-M - A145-M
3
Table of Contents
3
Operation Manual / A130-M
6
Introduction
6
Purpose of the Manual
6
Fig. 1: Serial Number (01) on the Rating Plate
6
Contact Information
7
Essential Information
7
Layout and Function of the Turbocharger
8
Fig. 2: Layout and Function of the Turbocharger
8
Fig. 3: Compressor Wheel Cooling
9
Symbols, Definitions
10
Table 1: Definition of Pictograms
11
Storage of New Turbochargers and Spare Parts
12
Fig. 4: Volatile Corrosion Inhibitor (VCI)
12
Fig. 5: Package with Hygrometer
13
Registered Trademarks
14
Safety
15
Introduction
15
CE Conformity
15
Definition of Mandatory Signs
16
Definition of Safety Instructions
16
Table 2: Personal Protective Equipment to be Worn at All Times
16
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
16
Intended Use
17
Deflagration on Gas Engines
18
Warning Plates on the Turbocharger
19
Fig. 6: Warning Plate Locations
19
Turbocharger Rating Plate
20
Fig. 7: Rating Plate
20
Fig. 8: Locations of the Rating Plates
21
Periodic Check of the Pressure Vessels
22
Lifting of Loads
23
Fig. 9: Attachment of Loads on the Crane Hook
23
Fig. 10: Attachment Angle
23
Prerequisites for Operation and Maintenance
24
Hazards During Operation and Maintenance
25
Safe Operation
27
Fig. 11
27
Safe Maintenance
28
Removing and Installing
32
Turbocharger Weight and Transportation
32
Fig. 12: Suspension of Complete Turbocharger Unit
32
Table 4: Weight of Complete Turbocharger Unit
32
Fig. 13: Turbine Cleaning Nozzle
33
Removing the Turbocharger
33
Fig. 14: Removing the Turbocharger
34
Fig. 15: Loosening the Clamping Nut
36
Fig. 16: Turbocharger Centre of Gravity
37
Installing the Turbocharger
38
Fig. 17: Inserting Gaskets into the Bracket
38
Fig. 18: Fitting Threaded Rods Onto the Bracket
39
Fig. 19: Requirements for Threaded Rods
39
Table 5: Requirements for Threaded Rods
39
Fig. 20: Placing the Turbocharger on the Bracket
40
Table 6: Tightening Torque for Standard Nuts
41
Fig. 21: Preparing the Clamping Nut for the Tightening Procedure
42
Fig. 22: Tightening Pressure Screws
43
Table 7: Torque-Controlled Tightening of the Pressure Screws
43
Fig. 23: Connecting the Speed Sensor
44
Fig. 24: Connecting the Compressor Cooling Air Intake
44
Fig. 25: Attaching the Support
45
Commissioning
46
Oil Supply
46
Fig. 26: Oil Orifice
46
Inspection Procedures
48
Commissioning after Taking out of Operation
50
Monitoring Operation
51
Oil Pressure, Oil Temperature
51
Table 8: Lubricating Oil Pressure at Oil Inlet before Turbocharger
51
Table 9: Lubricating Oil Temperature at the Inlet
52
Table 10: Lubricating Oil Temperature at the Outlet
52
Exhaust Gas Temperature before Turbine
53
Fig. 27: Layout and Overview of Speed Measurement System
54
Turbocharger Speed
54
Fig. 28: Replacing the Speed Sensor
56
Table 11: Tightening Torque (86505)
56
Operation and Service
57
Noise Emission
57
Fig. 29: Noise Insulation, Bellows
58
Service Work
59
Fig. 30: Replacing the Protective Grid
61
Expected Replacement Intervals
63
Table 12: Expected Replacement Intervals
63
Stopping the Engine
65
Periodic Maintenance Work
66
Foreword to Maintenance
66
Table 13: Maintenance Table
66
Cleaning the Compressor During Operation
67
Fig. 31: Carrying out Wet Cleaning of Compressor
69
Table 14: Parameters for Wet Cleaning of Compressor
69
Cleaning the Turbine During Operation
70
Table 15: Turbine Wet Cleaning, Recommended Operating State
72
Fig. 32: Carrying out Wet Cleaning of Turbine
73
Table 16: Wet Cleaning of Turbine, Parameters
73
Cleaning Components Mechanically
74
Fig. 33: Cleaning the Filter Silencer
75
Fig. 34: Compressor-End, Non-Rotating Parts
77
Fig. 35: Turbine End, Non-Rotating Parts
78
Fig. 36: Soaking the Turbine End
81
Table 17: Value Table for Soaking
81
Table 20: Malfunctions When Starting - Rubbing of Rotating Parts
84
Table 19: Malfunctions When Starting - Vibrations
84
Table 18: Malfunctions When Starting - Delayed Start-Up
84
Malfunctions When Starting
84
Eliminating Malfunctions
84
Malfunctions During Operation
85
Table 21: Malfunctions During Operation - Lubricating Oil Pressure too Low
85
Table 22: Malfunctions During Operation - Speed Reduces
85
Table 23: Malfunctions During Operation - Speed Increases
85
Table 24: Malfunctions During Operation - Exhaust Gas Temperature too High
86
Table 25: Malfunctions During Operation - Charge Air Pressure too Low
86
Table 26: Malfunctions During Operation - Charge Air Pressure too High
87
Table 27: Malfunctions During Operation - Engine Performance Losses
87
Turbocharger Is Surging
88
Table 28: Malfunction - Turbocharger Surging
88
Table 29: Malfunction - Sporadic Surge Blows
88
Table 31: Malfunctions When Stopping - Runout Time too Short
89
Table 30: Malfunctions When Stopping - Runout Noises
89
Malfunctions When Stopping
89
Speed Measurement System
90
Table 32: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
90
Table 33: Malfunction of the Speed Measurement System - Measured Speed too High
90
Table 34: Malfunction of the Speed Measurement System - Measured Speed too Low
90
Dismantling and Fitting
91
Introduction
91
Material Required
92
Fig. 37: Swivel Lifting Eye (Example)
92
Table 35: Swivel Lifting Eyes
92
Fig. 38: Starpoint Ring Nut VRM
93
ABB A135-M66 Operation Manual (152 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 19.1 MB
Table of Contents
Operation Manual / A130-M - A145-M
3
Table of Contents
3
Operation Manual / A130-M
6
Introduction
6
Purpose of the Manual
6
Fig. 1: Serial Number (01) on the Rating Plate
6
Contact Information
7
Essential Information
7
Layout and Function of the Turbocharger
8
Fig. 2: Layout and Function of the Turbocharger
8
Fig. 3: Compressor Wheel Cooling
9
Symbols, Definitions
10
Table 1: Definition of Pictograms
11
Storage of New Turbochargers and Spare Parts
12
Fig. 4: Volatile Corrosion Inhibitor (VCI)
12
Fig. 5: Package with Hygrometer
13
Registered Trademarks
14
Safety
15
Introduction
15
CE Conformity
15
Definition of Mandatory Signs
16
Definition of Safety Instructions
16
Table 2: Personal Protective Equipment to be Worn at All Times
16
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
16
Intended Use
17
Deflagration on Gas Engines
18
Warning Plates on the Turbocharger
19
Fig. 6: Warning Plate Locations
19
Turbocharger Rating Plate
20
Fig. 7: Rating Plate
20
Fig. 8: Locations of the Rating Plates
21
Periodic Check of the Pressure Vessels
22
Lifting of Loads
23
Fig. 9: Attachment of Loads on the Crane Hook
23
Fig. 10: Attachment Angle
23
Prerequisites for Operation and Maintenance
24
Hazards During Operation and Maintenance
25
Safe Operation
27
Fig. 11
27
Safe Maintenance
28
Removing and Installing
32
Turbocharger Weight and Transportation
32
Fig. 12: Suspension of Complete Turbocharger Unit
32
Table 4: Weight of Complete Turbocharger Unit
32
Fig. 13: Turbine Cleaning Nozzle
33
Removing the Turbocharger
33
Fig. 14: Removing the Turbocharger
34
Fig. 15: Loosening the Clamping Nut
36
Fig. 16: Turbocharger Centre of Gravity
37
Installing the Turbocharger
38
Fig. 17: Inserting Gaskets into the Bracket
38
Fig. 18: Fitting Threaded Rods Onto the Bracket
39
Fig. 19: Requirements for Threaded Rods
39
Table 5: Requirements for Threaded Rods
39
Fig. 20: Placing the Turbocharger on the Bracket
40
Table 6: Tightening Torque for Standard Nuts
41
Fig. 21: Preparing the Clamping Nut for the Tightening Procedure
42
Fig. 22: Tightening Pressure Screws
43
Table 7: Torque-Controlled Tightening of the Pressure Screws
43
Fig. 23: Connecting the Speed Sensor
44
Fig. 24: Connecting the Compressor Cooling Air Intake
44
Fig. 25: Attaching the Support
45
Commissioning
46
Oil Supply
46
Fig. 26: Oil Orifice
46
Inspection Procedures
48
Commissioning after Taking out of Operation
50
Monitoring Operation
51
Oil Pressure, Oil Temperature
51
Table 8: Lubricating Oil Pressure at Oil Inlet before Turbocharger
51
Table 9: Lubricating Oil Temperature at the Inlet
52
Table 10: Lubricating Oil Temperature at the Outlet
52
Exhaust Gas Temperature before Turbine
53
Fig. 27: Layout and Overview of Speed Measurement System
54
Turbocharger Speed
54
Fig. 28: Replacing the Speed Sensor
56
Table 11: Tightening Torque (86505)
56
Operation and Service
57
Noise Emission
57
Fig. 29: Noise Insulation, Bellows
58
Service Work
59
Fig. 30: Replacing the Protective Grid
61
Expected Replacement Intervals
63
Table 12: Expected Replacement Intervals
63
Stopping the Engine
65
Periodic Maintenance Work
66
Foreword to Maintenance
66
Table 13: Maintenance Table
66
Cleaning the Compressor During Operation
67
Fig. 31: Carrying out Wet Cleaning of Compressor
69
Table 14: Parameters for Wet Cleaning of Compressor
69
Cleaning the Turbine During Operation
70
Table 15: Turbine Wet Cleaning, Recommended Operating State
72
Fig. 32: Carrying out Wet Cleaning of Turbine
73
Table 16: Wet Cleaning of Turbine, Parameters
73
Cleaning Components Mechanically
74
Fig. 33: Cleaning the Filter Silencer
75
Fig. 34: Compressor-End, Non-Rotating Parts
77
Fig. 35: Turbine End, Non-Rotating Parts
78
Fig. 36: Soaking the Turbine End
81
Table 17: Value Table for Soaking
81
Table 20: Malfunctions When Starting - Rubbing of Rotating Parts
84
Table 19: Malfunctions When Starting - Vibrations
84
Table 18: Malfunctions When Starting - Delayed Start-Up
84
Malfunctions When Starting
84
Eliminating Malfunctions
84
Malfunctions During Operation
85
Table 21: Malfunctions During Operation - Lubricating Oil Pressure too Low
85
Table 22: Malfunctions During Operation - Speed Reduces
85
Table 23: Malfunctions During Operation - Speed Increases
85
Table 24: Malfunctions During Operation - Exhaust Gas Temperature too High
86
Table 25: Malfunctions During Operation - Charge Air Pressure too Low
86
Table 26: Malfunctions During Operation - Charge Air Pressure too High
87
Table 27: Malfunctions During Operation - Engine Performance Losses
87
Turbocharger Is Surging
88
Table 28: Malfunction - Turbocharger Surging
88
Table 29: Malfunction - Sporadic Surge Blows
88
Table 31: Malfunctions When Stopping - Runout Time too Short
89
Table 30: Malfunctions When Stopping - Runout Noises
89
Malfunctions When Stopping
89
Speed Measurement System
90
Table 32: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
90
Table 33: Malfunction of the Speed Measurement System - Measured Speed too High
90
Table 34: Malfunction of the Speed Measurement System - Measured Speed too Low
90
Dismantling and Fitting
91
Introduction
91
Material Required
92
Fig. 37: Swivel Lifting Eye (Example)
92
Table 35: Swivel Lifting Eyes
92
Fig. 38: Starpoint Ring Nut VRM
93
ABB A135-M66 Operation Manual (152 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 19.1 MB
Table of Contents
Operation Manual / A130-M - A145-M
3
Table of Contents
3
Operation Manual / A130-M
6
Introduction
6
Purpose of the Manual
6
Fig. 1: Serial Number (01) on the Rating Plate
6
Contact Information
7
Essential Information
7
Layout and Function of the Turbocharger
8
Fig. 2: Layout and Function of the Turbocharger
8
Fig. 3: Compressor Wheel Cooling
9
Symbols, Definitions
10
Table 1: Definition of Pictograms
11
Storage of New Turbochargers and Spare Parts
12
Fig. 4: Volatile Corrosion Inhibitor (VCI)
12
Fig. 5: Package with Hygrometer
13
Registered Trademarks
14
Safety
15
Introduction
15
CE Conformity
15
Definition of Mandatory Signs
16
Definition of Safety Instructions
16
Table 2: Personal Protective Equipment to be Worn at All Times
16
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
16
Intended Use
17
Deflagration on Gas Engines
18
Warning Plates on the Turbocharger
19
Fig. 6: Warning Plate Locations
19
Turbocharger Rating Plate
20
Fig. 7: Rating Plate
20
Fig. 8: Locations of the Rating Plates
21
Periodic Check of the Pressure Vessels
22
Lifting of Loads
23
Fig. 9: Attachment of Loads on the Crane Hook
23
Fig. 10: Attachment Angle
23
Prerequisites for Operation and Maintenance
24
Hazards During Operation and Maintenance
25
Safe Operation
27
Fig. 11
27
Safe Maintenance
28
Removing and Installing
32
Turbocharger Weight and Transportation
32
Fig. 12: Suspension of Complete Turbocharger Unit
32
Table 4: Weight of Complete Turbocharger Unit
32
Fig. 13: Turbine Cleaning Nozzle
33
Removing the Turbocharger
33
Fig. 14: Removing the Turbocharger
34
Fig. 15: Loosening the Clamping Nut
36
Fig. 16: Turbocharger Centre of Gravity
37
Installing the Turbocharger
38
Fig. 17: Inserting Gaskets into the Bracket
38
Fig. 18: Fitting Threaded Rods Onto the Bracket
39
Fig. 19: Requirements for Threaded Rods
39
Table 5: Requirements for Threaded Rods
39
Fig. 20: Placing the Turbocharger on the Bracket
40
Table 6: Tightening Torque for Standard Nuts
41
Fig. 21: Preparing the Clamping Nut for the Tightening Procedure
42
Fig. 22: Tightening Pressure Screws
43
Table 7: Torque-Controlled Tightening of the Pressure Screws
43
Fig. 23: Connecting the Speed Sensor
44
Fig. 24: Connecting the Compressor Cooling Air Intake
44
Fig. 25: Attaching the Support
45
Commissioning
46
Oil Supply
46
Fig. 26: Oil Orifice
46
Inspection Procedures
48
Commissioning after Taking out of Operation
50
Monitoring Operation
51
Oil Pressure, Oil Temperature
51
Table 8: Lubricating Oil Pressure at Oil Inlet before Turbocharger
51
Table 9: Lubricating Oil Temperature at the Inlet
52
Table 10: Lubricating Oil Temperature at the Outlet
52
Exhaust Gas Temperature before Turbine
53
Fig. 27: Layout and Overview of Speed Measurement System
54
Turbocharger Speed
54
Fig. 28: Replacing the Speed Sensor
56
Table 11: Tightening Torque (86505)
56
Operation and Service
57
Noise Emission
57
Fig. 29: Noise Insulation, Bellows
58
Service Work
59
Fig. 30: Replacing the Protective Grid
61
Expected Replacement Intervals
63
Table 12: Expected Replacement Intervals
63
Stopping the Engine
65
Periodic Maintenance Work
66
Foreword to Maintenance
66
Table 13: Maintenance Table
66
Cleaning the Compressor During Operation
67
Fig. 31: Carrying out Wet Cleaning of Compressor
69
Table 14: Parameters for Wet Cleaning of Compressor
69
Cleaning the Turbine During Operation
70
Table 15: Turbine Wet Cleaning, Recommended Operating State
72
Fig. 32: Carrying out Wet Cleaning of Turbine
73
Table 16: Wet Cleaning of Turbine, Parameters
73
Cleaning Components Mechanically
74
Fig. 33: Cleaning the Filter Silencer
75
Fig. 34: Compressor-End, Non-Rotating Parts
77
Fig. 35: Turbine End, Non-Rotating Parts
78
Fig. 36: Soaking the Turbine End
81
Table 17: Value Table for Soaking
81
Table 20: Malfunctions When Starting - Rubbing of Rotating Parts
84
Table 19: Malfunctions When Starting - Vibrations
84
Table 18: Malfunctions When Starting - Delayed Start-Up
84
Malfunctions When Starting
84
Eliminating Malfunctions
84
Malfunctions During Operation
85
Table 21: Malfunctions During Operation - Lubricating Oil Pressure too Low
85
Table 22: Malfunctions During Operation - Speed Reduces
85
Table 23: Malfunctions During Operation - Speed Increases
85
Table 24: Malfunctions During Operation - Exhaust Gas Temperature too High
86
Table 25: Malfunctions During Operation - Charge Air Pressure too Low
86
Table 26: Malfunctions During Operation - Charge Air Pressure too High
87
Table 27: Malfunctions During Operation - Engine Performance Losses
87
Turbocharger Is Surging
88
Table 28: Malfunction - Turbocharger Surging
88
Table 29: Malfunction - Sporadic Surge Blows
88
Table 31: Malfunctions When Stopping - Runout Time too Short
89
Table 30: Malfunctions When Stopping - Runout Noises
89
Malfunctions When Stopping
89
Speed Measurement System
90
Table 32: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
90
Table 33: Malfunction of the Speed Measurement System - Measured Speed too High
90
Table 34: Malfunction of the Speed Measurement System - Measured Speed too Low
90
Dismantling and Fitting
91
Introduction
91
Material Required
92
Fig. 37: Swivel Lifting Eye (Example)
92
Table 35: Swivel Lifting Eyes
92
Fig. 38: Starpoint Ring Nut VRM
93
ABB A135-M66 Operation Manual (152 pages)
Turbocharging
Brand:
ABB
| Category:
Industrial Equipment
| Size: 19.1 MB
Table of Contents
Operation Manual / A130-M - A145-M
3
Table of Contents
3
Operation Manual / A130-M
6
Introduction
6
Purpose of the Manual
6
Fig. 1: Serial Number (01) on the Rating Plate
6
Contact Information
7
Essential Information
7
Layout and Function of the Turbocharger
8
Fig. 2: Layout and Function of the Turbocharger
8
Fig. 3: Compressor Wheel Cooling
9
Symbols, Definitions
10
Table 1: Definition of Pictograms
11
Storage of New Turbochargers and Spare Parts
12
Fig. 4: Volatile Corrosion Inhibitor (VCI)
12
Fig. 5: Package with Hygrometer
13
Registered Trademarks
14
Safety
15
Introduction
15
CE Conformity
15
Definition of Mandatory Signs
16
Definition of Safety Instructions
16
Table 2: Personal Protective Equipment to be Worn at All Times
16
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
16
Intended Use
17
Deflagration on Gas Engines
18
Warning Plates on the Turbocharger
19
Fig. 6: Warning Plate Locations
19
Turbocharger Rating Plate
20
Fig. 7: Rating Plate
20
Fig. 8: Locations of the Rating Plates
21
Periodic Check of the Pressure Vessels
22
Lifting of Loads
23
Fig. 9: Attachment of Loads on the Crane Hook
23
Fig. 10: Attachment Angle
23
Prerequisites for Operation and Maintenance
24
Hazards During Operation and Maintenance
25
Safe Operation
27
Fig. 11
27
Safe Maintenance
28
Removing and Installing
32
Turbocharger Weight and Transportation
32
Fig. 12: Suspension of Complete Turbocharger Unit
32
Table 4: Weight of Complete Turbocharger Unit
32
Fig. 13: Turbine Cleaning Nozzle
33
Removing the Turbocharger
33
Fig. 14: Removing the Turbocharger
34
Fig. 15: Loosening the Clamping Nut
36
Fig. 16: Turbocharger Centre of Gravity
37
Installing the Turbocharger
38
Fig. 17: Inserting Gaskets into the Bracket
38
Fig. 18: Fitting Threaded Rods Onto the Bracket
39
Fig. 19: Requirements for Threaded Rods
39
Table 5: Requirements for Threaded Rods
39
Fig. 20: Placing the Turbocharger on the Bracket
40
Table 6: Tightening Torque for Standard Nuts
41
Fig. 21: Preparing the Clamping Nut for the Tightening Procedure
42
Fig. 22: Tightening Pressure Screws
43
Table 7: Torque-Controlled Tightening of the Pressure Screws
43
Fig. 23: Connecting the Speed Sensor
44
Fig. 24: Connecting the Compressor Cooling Air Intake
44
Fig. 25: Attaching the Support
45
Commissioning
46
Oil Supply
46
Fig. 26: Oil Orifice
46
Inspection Procedures
48
Commissioning after Taking out of Operation
50
Monitoring Operation
51
Oil Pressure, Oil Temperature
51
Table 8: Lubricating Oil Pressure at Oil Inlet before Turbocharger
51
Table 9: Lubricating Oil Temperature at the Inlet
52
Table 10: Lubricating Oil Temperature at the Outlet
52
Exhaust Gas Temperature before Turbine
53
Fig. 27: Layout and Overview of Speed Measurement System
54
Turbocharger Speed
54
Fig. 28: Replacing the Speed Sensor
56
Table 11: Tightening Torque (86505)
56
Operation and Service
57
Noise Emission
57
Fig. 29: Noise Insulation, Bellows
58
Service Work
59
Fig. 30: Replacing the Protective Grid
61
Expected Replacement Intervals
63
Table 12: Expected Replacement Intervals
63
Stopping the Engine
65
Periodic Maintenance Work
66
Foreword to Maintenance
66
Table 13: Maintenance Table
66
Cleaning the Compressor During Operation
67
Fig. 31: Carrying out Wet Cleaning of Compressor
69
Table 14: Parameters for Wet Cleaning of Compressor
69
Cleaning the Turbine During Operation
70
Table 15: Turbine Wet Cleaning, Recommended Operating State
72
Fig. 32: Carrying out Wet Cleaning of Turbine
73
Table 16: Wet Cleaning of Turbine, Parameters
73
Cleaning Components Mechanically
74
Fig. 33: Cleaning the Filter Silencer
75
Fig. 34: Compressor-End, Non-Rotating Parts
77
Fig. 35: Turbine End, Non-Rotating Parts
78
Fig. 36: Soaking the Turbine End
81
Table 17: Value Table for Soaking
81
Table 20: Malfunctions When Starting - Rubbing of Rotating Parts
84
Table 19: Malfunctions When Starting - Vibrations
84
Table 18: Malfunctions When Starting - Delayed Start-Up
84
Malfunctions When Starting
84
Eliminating Malfunctions
84
Malfunctions During Operation
85
Table 21: Malfunctions During Operation - Lubricating Oil Pressure too Low
85
Table 22: Malfunctions During Operation - Speed Reduces
85
Table 23: Malfunctions During Operation - Speed Increases
85
Table 24: Malfunctions During Operation - Exhaust Gas Temperature too High
86
Table 25: Malfunctions During Operation - Charge Air Pressure too Low
86
Table 26: Malfunctions During Operation - Charge Air Pressure too High
87
Table 27: Malfunctions During Operation - Engine Performance Losses
87
Turbocharger Is Surging
88
Table 28: Malfunction - Turbocharger Surging
88
Table 29: Malfunction - Sporadic Surge Blows
88
Table 31: Malfunctions When Stopping - Runout Time too Short
89
Table 30: Malfunctions When Stopping - Runout Noises
89
Malfunctions When Stopping
89
Speed Measurement System
90
Table 32: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
90
Table 33: Malfunction of the Speed Measurement System - Measured Speed too High
90
Table 34: Malfunction of the Speed Measurement System - Measured Speed too Low
90
Dismantling and Fitting
91
Introduction
91
Material Required
92
Fig. 37: Swivel Lifting Eye (Example)
92
Table 35: Swivel Lifting Eyes
92
Fig. 38: Starpoint Ring Nut VRM
93
ABB A135-M66 Operation Manual (152 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 19.1 MB
Table of Contents
Operation Manual / A130-M - A145-M
3
Table of Contents
3
Operation Manual / A130-M
6
Introduction
6
Purpose of the Manual
6
Fig. 1: Serial Number (01) on the Rating Plate
6
Contact Information
7
Essential Information
7
Layout and Function of the Turbocharger
8
Fig. 2: Layout and Function of the Turbocharger
8
Fig. 3: Compressor Wheel Cooling
9
Symbols, Definitions
10
Table 1: Definition of Pictograms
11
Storage of New Turbochargers and Spare Parts
12
Fig. 4: Volatile Corrosion Inhibitor (VCI)
12
Fig. 5: Package with Hygrometer
13
Registered Trademarks
14
Safety
15
Introduction
15
CE Conformity
15
Definition of Mandatory Signs
16
Definition of Safety Instructions
16
Table 2: Personal Protective Equipment to be Worn at All Times
16
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
16
Intended Use
17
Deflagration on Gas Engines
18
Warning Plates on the Turbocharger
19
Fig. 6: Warning Plate Locations
19
Turbocharger Rating Plate
20
Fig. 7: Rating Plate
20
Fig. 8: Locations of the Rating Plates
21
Periodic Check of the Pressure Vessels
22
Lifting of Loads
23
Fig. 9: Attachment of Loads on the Crane Hook
23
Fig. 10: Attachment Angle
23
Prerequisites for Operation and Maintenance
24
Hazards During Operation and Maintenance
25
Safe Operation
27
Fig. 11
27
Safe Maintenance
28
Removing and Installing
32
Turbocharger Weight and Transportation
32
Fig. 12: Suspension of Complete Turbocharger Unit
32
Table 4: Weight of Complete Turbocharger Unit
32
Fig. 13: Turbine Cleaning Nozzle
33
Removing the Turbocharger
33
Fig. 14: Removing the Turbocharger
34
Fig. 15: Loosening the Clamping Nut
36
Fig. 16: Turbocharger Centre of Gravity
37
Installing the Turbocharger
38
Fig. 17: Inserting Gaskets into the Bracket
38
Fig. 18: Fitting Threaded Rods Onto the Bracket
39
Fig. 19: Requirements for Threaded Rods
39
Table 5: Requirements for Threaded Rods
39
Fig. 20: Placing the Turbocharger on the Bracket
40
Table 6: Tightening Torque for Standard Nuts
41
Fig. 21: Preparing the Clamping Nut for the Tightening Procedure
42
Fig. 22: Tightening Pressure Screws
43
Table 7: Torque-Controlled Tightening of the Pressure Screws
43
Fig. 23: Connecting the Speed Sensor
44
Fig. 24: Connecting the Compressor Cooling Air Intake
44
Fig. 25: Attaching the Support
45
Commissioning
46
Oil Supply
46
Fig. 26: Oil Orifice
46
Inspection Procedures
48
Commissioning after Taking out of Operation
50
Monitoring Operation
51
Oil Pressure, Oil Temperature
51
Table 8: Lubricating Oil Pressure at Oil Inlet before Turbocharger
51
Table 9: Lubricating Oil Temperature at the Inlet
52
Table 10: Lubricating Oil Temperature at the Outlet
52
Exhaust Gas Temperature before Turbine
53
Fig. 27: Layout and Overview of Speed Measurement System
54
Turbocharger Speed
54
Fig. 28: Replacing the Speed Sensor
56
Table 11: Tightening Torque (86505)
56
Operation and Service
57
Noise Emission
57
Fig. 29: Noise Insulation, Bellows
58
Service Work
59
Fig. 30: Replacing the Protective Grid
61
Expected Replacement Intervals
63
Table 12: Expected Replacement Intervals
63
Stopping the Engine
65
Periodic Maintenance Work
66
Foreword to Maintenance
66
Table 13: Maintenance Table
66
Cleaning the Compressor During Operation
67
Fig. 31: Carrying out Wet Cleaning of Compressor
69
Table 14: Parameters for Wet Cleaning of Compressor
69
Cleaning the Turbine During Operation
70
Table 15: Turbine Wet Cleaning, Recommended Operating State
72
Fig. 32: Carrying out Wet Cleaning of Turbine
73
Table 16: Wet Cleaning of Turbine, Parameters
73
Cleaning Components Mechanically
74
Fig. 33: Cleaning the Filter Silencer
75
Fig. 34: Compressor-End, Non-Rotating Parts
77
Fig. 35: Turbine End, Non-Rotating Parts
78
Fig. 36: Soaking the Turbine End
81
Table 17: Value Table for Soaking
81
Table 20: Malfunctions When Starting - Rubbing of Rotating Parts
84
Table 19: Malfunctions When Starting - Vibrations
84
Table 18: Malfunctions When Starting - Delayed Start-Up
84
Malfunctions When Starting
84
Eliminating Malfunctions
84
Malfunctions During Operation
85
Table 21: Malfunctions During Operation - Lubricating Oil Pressure too Low
85
Table 22: Malfunctions During Operation - Speed Reduces
85
Table 23: Malfunctions During Operation - Speed Increases
85
Table 24: Malfunctions During Operation - Exhaust Gas Temperature too High
86
Table 25: Malfunctions During Operation - Charge Air Pressure too Low
86
Table 26: Malfunctions During Operation - Charge Air Pressure too High
87
Table 27: Malfunctions During Operation - Engine Performance Losses
87
Turbocharger Is Surging
88
Table 28: Malfunction - Turbocharger Surging
88
Table 29: Malfunction - Sporadic Surge Blows
88
Table 31: Malfunctions When Stopping - Runout Time too Short
89
Table 30: Malfunctions When Stopping - Runout Noises
89
Malfunctions When Stopping
89
Speed Measurement System
90
Table 32: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
90
Table 33: Malfunction of the Speed Measurement System - Measured Speed too High
90
Table 34: Malfunction of the Speed Measurement System - Measured Speed too Low
90
Dismantling and Fitting
91
Introduction
91
Material Required
92
Fig. 37: Swivel Lifting Eye (Example)
92
Table 35: Swivel Lifting Eyes
92
Fig. 38: Starpoint Ring Nut VRM
93
ABB A135-M66 Operation Manual (152 pages)
Turbo Systems
Brand:
ABB
| Category:
Industrial Equipment
| Size: 19.1 MB
Table of Contents
Operation Manual / A130-M - A145-M
3
Table of Contents
3
Operation Manual / A130-M
6
Introduction
6
Purpose of the Manual
6
Fig. 1: Serial Number (01) on the Rating Plate
6
Contact Information
7
Essential Information
7
Layout and Function of the Turbocharger
8
Fig. 2: Layout and Function of the Turbocharger
8
Fig. 3: Compressor Wheel Cooling
9
Symbols, Definitions
10
Table 1: Definition of Pictograms
11
Storage of New Turbochargers and Spare Parts
12
Fig. 4: Volatile Corrosion Inhibitor (VCI)
12
Fig. 5: Package with Hygrometer
13
Registered Trademarks
14
Safety
15
Introduction
15
CE Conformity
15
Definition of Mandatory Signs
16
Definition of Safety Instructions
16
Table 2: Personal Protective Equipment to be Worn at All Times
16
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
16
Intended Use
17
Deflagration on Gas Engines
18
Warning Plates on the Turbocharger
19
Fig. 6: Warning Plate Locations
19
Turbocharger Rating Plate
20
Fig. 7: Rating Plate
20
Fig. 8: Locations of the Rating Plates
21
Periodic Check of the Pressure Vessels
22
Lifting of Loads
23
Fig. 9: Attachment of Loads on the Crane Hook
23
Fig. 10: Attachment Angle
23
Prerequisites for Operation and Maintenance
24
Hazards During Operation and Maintenance
25
Safe Operation
27
Fig. 11
27
Safe Maintenance
28
Removing and Installing
32
Turbocharger Weight and Transportation
32
Fig. 12: Suspension of Complete Turbocharger Unit
32
Table 4: Weight of Complete Turbocharger Unit
32
Fig. 13: Turbine Cleaning Nozzle
33
Removing the Turbocharger
33
Fig. 14: Removing the Turbocharger
34
Fig. 15: Loosening the Clamping Nut
36
Fig. 16: Turbocharger Centre of Gravity
37
Installing the Turbocharger
38
Fig. 17: Inserting Gaskets into the Bracket
38
Fig. 18: Fitting Threaded Rods Onto the Bracket
39
Fig. 19: Requirements for Threaded Rods
39
Table 5: Requirements for Threaded Rods
39
Fig. 20: Placing the Turbocharger on the Bracket
40
Table 6: Tightening Torque for Standard Nuts
41
Fig. 21: Preparing the Clamping Nut for the Tightening Procedure
42
Fig. 22: Tightening Pressure Screws
43
Table 7: Torque-Controlled Tightening of the Pressure Screws
43
Fig. 23: Connecting the Speed Sensor
44
Fig. 24: Connecting the Compressor Cooling Air Intake
44
Fig. 25: Attaching the Support
45
Commissioning
46
Oil Supply
46
Fig. 26: Oil Orifice
46
Inspection Procedures
48
Commissioning after Taking out of Operation
50
Monitoring Operation
51
Oil Pressure, Oil Temperature
51
Table 8: Lubricating Oil Pressure at Oil Inlet before Turbocharger
51
Table 9: Lubricating Oil Temperature at the Inlet
52
Table 10: Lubricating Oil Temperature at the Outlet
52
Exhaust Gas Temperature before Turbine
53
Fig. 27: Layout and Overview of Speed Measurement System
54
Turbocharger Speed
54
Fig. 28: Replacing the Speed Sensor
56
Table 11: Tightening Torque (86505)
56
Operation and Service
57
Noise Emission
57
Fig. 29: Noise Insulation, Bellows
58
Service Work
59
Fig. 30: Replacing the Protective Grid
61
Expected Replacement Intervals
63
Table 12: Expected Replacement Intervals
63
Stopping the Engine
65
Periodic Maintenance Work
66
Foreword to Maintenance
66
Table 13: Maintenance Table
66
Cleaning the Compressor During Operation
67
Fig. 31: Carrying out Wet Cleaning of Compressor
69
Table 14: Parameters for Wet Cleaning of Compressor
69
Cleaning the Turbine During Operation
70
Table 15: Turbine Wet Cleaning, Recommended Operating State
72
Fig. 32: Carrying out Wet Cleaning of Turbine
73
Table 16: Wet Cleaning of Turbine, Parameters
73
Cleaning Components Mechanically
74
Fig. 33: Cleaning the Filter Silencer
75
Fig. 34: Compressor-End, Non-Rotating Parts
77
Fig. 35: Turbine End, Non-Rotating Parts
78
Fig. 36: Soaking the Turbine End
81
Table 17: Value Table for Soaking
81
Table 20: Malfunctions When Starting - Rubbing of Rotating Parts
84
Table 19: Malfunctions When Starting - Vibrations
84
Table 18: Malfunctions When Starting - Delayed Start-Up
84
Malfunctions When Starting
84
Eliminating Malfunctions
84
Malfunctions During Operation
85
Table 21: Malfunctions During Operation - Lubricating Oil Pressure too Low
85
Table 22: Malfunctions During Operation - Speed Reduces
85
Table 23: Malfunctions During Operation - Speed Increases
85
Table 24: Malfunctions During Operation - Exhaust Gas Temperature too High
86
Table 25: Malfunctions During Operation - Charge Air Pressure too Low
86
Table 26: Malfunctions During Operation - Charge Air Pressure too High
87
Table 27: Malfunctions During Operation - Engine Performance Losses
87
Turbocharger Is Surging
88
Table 28: Malfunction - Turbocharger Surging
88
Table 29: Malfunction - Sporadic Surge Blows
88
Table 31: Malfunctions When Stopping - Runout Time too Short
89
Table 30: Malfunctions When Stopping - Runout Noises
89
Malfunctions When Stopping
89
Speed Measurement System
90
Table 32: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
90
Table 33: Malfunction of the Speed Measurement System - Measured Speed too High
90
Table 34: Malfunction of the Speed Measurement System - Measured Speed too Low
90
Dismantling and Fitting
91
Introduction
91
Material Required
92
Fig. 37: Swivel Lifting Eye (Example)
92
Table 35: Swivel Lifting Eyes
92
Fig. 38: Starpoint Ring Nut VRM
93
ABB A135-M66 Operation Manual (152 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 19.1 MB
Table of Contents
Operation Manual / A130-M - A145-M
3
Table of Contents
3
Operation Manual / A130-M
6
Introduction
6
Purpose of the Manual
6
Fig. 1: Serial Number (01) on the Rating Plate
6
Contact Information
7
Essential Information
7
Layout and Function of the Turbocharger
8
Fig. 2: Layout and Function of the Turbocharger
8
Fig. 3: Compressor Wheel Cooling
9
Symbols, Definitions
10
Table 1: Definition of Pictograms
11
Storage of New Turbochargers and Spare Parts
12
Fig. 4: Volatile Corrosion Inhibitor (VCI)
12
Fig. 5: Package with Hygrometer
13
Registered Trademarks
14
Safety
15
Introduction
15
CE Conformity
15
Definition of Mandatory Signs
16
Definition of Safety Instructions
16
Table 2: Personal Protective Equipment to be Worn at All Times
16
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
16
Intended Use
17
Deflagration on Gas Engines
18
Warning Plates on the Turbocharger
19
Fig. 6: Warning Plate Locations
19
Turbocharger Rating Plate
20
Fig. 7: Rating Plate
20
Fig. 8: Locations of the Rating Plates
21
Periodic Check of the Pressure Vessels
22
Lifting of Loads
23
Fig. 9: Attachment of Loads on the Crane Hook
23
Fig. 10: Attachment Angle
23
Prerequisites for Operation and Maintenance
24
Hazards During Operation and Maintenance
25
Safe Operation
27
Fig. 11
27
Safe Maintenance
28
Removing and Installing
32
Turbocharger Weight and Transportation
32
Fig. 12: Suspension of Complete Turbocharger Unit
32
Table 4: Weight of Complete Turbocharger Unit
32
Fig. 13: Turbine Cleaning Nozzle
33
Removing the Turbocharger
33
Fig. 14: Removing the Turbocharger
34
Fig. 15: Loosening the Clamping Nut
36
Fig. 16: Turbocharger Centre of Gravity
37
Installing the Turbocharger
38
Fig. 17: Inserting Gaskets into the Bracket
38
Fig. 18: Fitting Threaded Rods Onto the Bracket
39
Fig. 19: Requirements for Threaded Rods
39
Table 5: Requirements for Threaded Rods
39
Fig. 20: Placing the Turbocharger on the Bracket
40
Table 6: Tightening Torque for Standard Nuts
41
Fig. 21: Preparing the Clamping Nut for the Tightening Procedure
42
Fig. 22: Tightening Pressure Screws
43
Table 7: Torque-Controlled Tightening of the Pressure Screws
43
Fig. 23: Connecting the Speed Sensor
44
Fig. 24: Connecting the Compressor Cooling Air Intake
44
Fig. 25: Attaching the Support
45
Commissioning
46
Oil Supply
46
Fig. 26: Oil Orifice
46
Inspection Procedures
48
Commissioning after Taking out of Operation
50
Monitoring Operation
51
Oil Pressure, Oil Temperature
51
Table 8: Lubricating Oil Pressure at Oil Inlet before Turbocharger
51
Table 9: Lubricating Oil Temperature at the Inlet
52
Table 10: Lubricating Oil Temperature at the Outlet
52
Exhaust Gas Temperature before Turbine
53
Fig. 27: Layout and Overview of Speed Measurement System
54
Turbocharger Speed
54
Fig. 28: Replacing the Speed Sensor
56
Table 11: Tightening Torque (86505)
56
Operation and Service
57
Noise Emission
57
Fig. 29: Noise Insulation, Bellows
58
Service Work
59
Fig. 30: Replacing the Protective Grid
61
Expected Replacement Intervals
63
Table 12: Expected Replacement Intervals
63
Stopping the Engine
65
Periodic Maintenance Work
66
Foreword to Maintenance
66
Table 13: Maintenance Table
66
Cleaning the Compressor During Operation
67
Fig. 31: Carrying out Wet Cleaning of Compressor
69
Table 14: Parameters for Wet Cleaning of Compressor
69
Cleaning the Turbine During Operation
70
Table 15: Turbine Wet Cleaning, Recommended Operating State
72
Fig. 32: Carrying out Wet Cleaning of Turbine
73
Table 16: Wet Cleaning of Turbine, Parameters
73
Cleaning Components Mechanically
74
Fig. 33: Cleaning the Filter Silencer
75
Fig. 34: Compressor-End, Non-Rotating Parts
77
Fig. 35: Turbine End, Non-Rotating Parts
78
Fig. 36: Soaking the Turbine End
81
Table 17: Value Table for Soaking
81
Table 20: Malfunctions When Starting - Rubbing of Rotating Parts
84
Table 19: Malfunctions When Starting - Vibrations
84
Table 18: Malfunctions When Starting - Delayed Start-Up
84
Malfunctions When Starting
84
Eliminating Malfunctions
84
Malfunctions During Operation
85
Table 21: Malfunctions During Operation - Lubricating Oil Pressure too Low
85
Table 22: Malfunctions During Operation - Speed Reduces
85
Table 23: Malfunctions During Operation - Speed Increases
85
Table 24: Malfunctions During Operation - Exhaust Gas Temperature too High
86
Table 25: Malfunctions During Operation - Charge Air Pressure too Low
86
Table 26: Malfunctions During Operation - Charge Air Pressure too High
87
Table 27: Malfunctions During Operation - Engine Performance Losses
87
Turbocharger Is Surging
88
Table 28: Malfunction - Turbocharger Surging
88
Table 29: Malfunction - Sporadic Surge Blows
88
Table 31: Malfunctions When Stopping - Runout Time too Short
89
Table 30: Malfunctions When Stopping - Runout Noises
89
Malfunctions When Stopping
89
Speed Measurement System
90
Table 32: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
90
Table 33: Malfunction of the Speed Measurement System - Measured Speed too High
90
Table 34: Malfunction of the Speed Measurement System - Measured Speed too Low
90
Dismantling and Fitting
91
Introduction
91
Material Required
92
Fig. 37: Swivel Lifting Eye (Example)
92
Table 35: Swivel Lifting Eyes
92
Fig. 38: Starpoint Ring Nut VRM
93
ABB A135-M66 Operation Manual (152 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 19.1 MB
Table of Contents
Operation Manual / A130-M - A145-M
3
Table of Contents
3
Operation Manual / A130-M
6
Introduction
6
Purpose of the Manual
6
Fig. 1: Serial Number (01) on the Rating Plate
6
Contact Information
7
Essential Information
7
Layout and Function of the Turbocharger
8
Fig. 2: Layout and Function of the Turbocharger
8
Fig. 3: Compressor Wheel Cooling
9
Symbols, Definitions
10
Table 1: Definition of Pictograms
11
Storage of New Turbochargers and Spare Parts
12
Fig. 4: Volatile Corrosion Inhibitor (VCI)
12
Fig. 5: Package with Hygrometer
13
Registered Trademarks
14
Safety
15
Introduction
15
CE Conformity
15
Definition of Mandatory Signs
16
Definition of Safety Instructions
16
Table 2: Personal Protective Equipment to be Worn at All Times
16
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
16
Intended Use
17
Deflagration on Gas Engines
18
Warning Plates on the Turbocharger
19
Fig. 6: Warning Plate Locations
19
Turbocharger Rating Plate
20
Fig. 7: Rating Plate
20
Fig. 8: Locations of the Rating Plates
21
Periodic Check of the Pressure Vessels
22
Lifting of Loads
23
Fig. 9: Attachment of Loads on the Crane Hook
23
Fig. 10: Attachment Angle
23
Prerequisites for Operation and Maintenance
24
Hazards During Operation and Maintenance
25
Safe Operation
27
Fig. 11
27
Safe Maintenance
28
Removing and Installing
32
Turbocharger Weight and Transportation
32
Fig. 12: Suspension of Complete Turbocharger Unit
32
Table 4: Weight of Complete Turbocharger Unit
32
Fig. 13: Turbine Cleaning Nozzle
33
Removing the Turbocharger
33
Fig. 14: Removing the Turbocharger
34
Fig. 15: Loosening the Clamping Nut
36
Fig. 16: Turbocharger Centre of Gravity
37
Installing the Turbocharger
38
Fig. 17: Inserting Gaskets into the Bracket
38
Fig. 18: Fitting Threaded Rods Onto the Bracket
39
Fig. 19: Requirements for Threaded Rods
39
Table 5: Requirements for Threaded Rods
39
Fig. 20: Placing the Turbocharger on the Bracket
40
Table 6: Tightening Torque for Standard Nuts
41
Fig. 21: Preparing the Clamping Nut for the Tightening Procedure
42
Fig. 22: Tightening Pressure Screws
43
Table 7: Torque-Controlled Tightening of the Pressure Screws
43
Fig. 23: Connecting the Speed Sensor
44
Fig. 24: Connecting the Compressor Cooling Air Intake
44
Fig. 25: Attaching the Support
45
Commissioning
46
Oil Supply
46
Fig. 26: Oil Orifice
46
Inspection Procedures
48
Commissioning after Taking out of Operation
50
Monitoring Operation
51
Oil Pressure, Oil Temperature
51
Table 8: Lubricating Oil Pressure at Oil Inlet before Turbocharger
51
Table 9: Lubricating Oil Temperature at the Inlet
52
Table 10: Lubricating Oil Temperature at the Outlet
52
Exhaust Gas Temperature before Turbine
53
Fig. 27: Layout and Overview of Speed Measurement System
54
Turbocharger Speed
54
Fig. 28: Replacing the Speed Sensor
56
Table 11: Tightening Torque (86505)
56
Operation and Service
57
Noise Emission
57
Fig. 29: Noise Insulation, Bellows
58
Service Work
59
Fig. 30: Replacing the Protective Grid
61
Expected Replacement Intervals
63
Table 12: Expected Replacement Intervals
63
Stopping the Engine
65
Periodic Maintenance Work
66
Foreword to Maintenance
66
Table 13: Maintenance Table
66
Cleaning the Compressor During Operation
67
Fig. 31: Carrying out Wet Cleaning of Compressor
69
Table 14: Parameters for Wet Cleaning of Compressor
69
Cleaning the Turbine During Operation
70
Table 15: Turbine Wet Cleaning, Recommended Operating State
72
Fig. 32: Carrying out Wet Cleaning of Turbine
73
Table 16: Wet Cleaning of Turbine, Parameters
73
Cleaning Components Mechanically
74
Fig. 33: Cleaning the Filter Silencer
75
Fig. 34: Compressor-End, Non-Rotating Parts
77
Fig. 35: Turbine End, Non-Rotating Parts
78
Fig. 36: Soaking the Turbine End
81
Table 17: Value Table for Soaking
81
Table 20: Malfunctions When Starting - Rubbing of Rotating Parts
84
Table 19: Malfunctions When Starting - Vibrations
84
Table 18: Malfunctions When Starting - Delayed Start-Up
84
Malfunctions When Starting
84
Eliminating Malfunctions
84
Malfunctions During Operation
85
Table 21: Malfunctions During Operation - Lubricating Oil Pressure too Low
85
Table 22: Malfunctions During Operation - Speed Reduces
85
Table 23: Malfunctions During Operation - Speed Increases
85
Table 24: Malfunctions During Operation - Exhaust Gas Temperature too High
86
Table 25: Malfunctions During Operation - Charge Air Pressure too Low
86
Table 26: Malfunctions During Operation - Charge Air Pressure too High
87
Table 27: Malfunctions During Operation - Engine Performance Losses
87
Turbocharger Is Surging
88
Table 28: Malfunction - Turbocharger Surging
88
Table 29: Malfunction - Sporadic Surge Blows
88
Table 31: Malfunctions When Stopping - Runout Time too Short
89
Table 30: Malfunctions When Stopping - Runout Noises
89
Malfunctions When Stopping
89
Speed Measurement System
90
Table 32: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
90
Table 33: Malfunction of the Speed Measurement System - Measured Speed too High
90
Table 34: Malfunction of the Speed Measurement System - Measured Speed too Low
90
Dismantling and Fitting
91
Introduction
91
Material Required
92
Fig. 37: Swivel Lifting Eye (Example)
92
Table 35: Swivel Lifting Eyes
92
Fig. 38: Starpoint Ring Nut VRM
93
ABB A135-M66 Operation Manual (152 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 19.21 MB
Table of Contents
Operation Manual / A130-M - A145-M
3
Table of Contents
3
Fig. 1: Serial Number (01) on the Rating Plate
6
Operation Manual / A130-M
6
Purpose of the Manual
6
Introduction
6
Contact Information
7
Essential Information
7
Layout and Function of the Turbocharger
8
Fig. 2: Layout and Function of the Turbocharger
8
Fig. 3: Compressor Wheel Cooling
9
Symbols, Definitions
10
Table 1: Definition of Pictograms
11
Storage of New Turbochargers and Spare Parts
12
Fig. 4: Volatile Corrosion Inhibitor (VCI)
12
Fig. 5: Package with Hygrometer
13
Registered Trademarks
14
CE Conformity
15
Safety
15
Introduction
15
Definition of Mandatory Signs
16
Definition of Safety Instructions
16
Table 2: Personal Protective Equipment to be Worn at All Times
16
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
16
Intended Use
17
Deflagration on Gas Engines
18
Warning Plates on the Turbocharger
19
Fig. 6: Warning Plate Locations
19
Turbocharger Rating Plate
20
Fig. 7: Rating Plate
20
Fig. 8: Locations of the Rating Plates
21
Periodic Check of the Pressure Vessels
22
Lifting of Loads
23
Fig. 9: Attachment of Loads on the Crane Hook
23
Fig. 10: Attachment Angle
23
Prerequisites for Operation and Maintenance
24
Hazards During Operation and Maintenance
25
Safe Operation
27
Fig. 11
27
Safe Maintenance
28
Removing and Installing
32
Turbocharger Weight and Transportation
32
Fig. 12: Suspension of Complete Turbocharger Unit
32
Table 4: Weight of Complete Turbocharger Unit
32
Fig. 13: Turbine Cleaning Nozzle
33
Removing the Turbocharger
33
Fig. 14: Removing the Turbocharger
34
Fig. 15: Loosening the Clamping Nut
36
Fig. 16: Turbocharger Centre of Gravity
37
Installing the Turbocharger
38
Fig. 17: Inserting Gaskets into the Bracket
38
Fig. 18: Inserting the Threaded Rods
39
Fig. 19: Requirements for Threaded Rods
39
Table 5: Requirements for Threaded Rods
39
Fig. 20: Placing the Turbocharger on the Bracket
40
Table 6: Tightening Torque for Standard Nuts
41
Fig. 21: Preparing the Clamping Nut for the Tightening Procedure
42
Fig. 22: Tightening Pressure Screws
43
Table 7: Torque-Controlled Tightening of the Pressure Screws
43
Fig. 23: Connecting the Speed Sensor
44
Fig. 24: Connecting the Compressor Cooling Air Intake
44
Fig. 25: Attaching the Support
45
Commissioning
46
Oil Supply
46
Fig. 26: Oil Orifice
47
Inspection Procedures
48
Commissioning after Taking out of Operation
50
Monitoring Operation
51
Oil Pressure, Oil Temperature
51
Table 8: Lubricating Oil Pressure at Oil Inlet before Turbocharger
51
Table 9: Lubricating Oil Temperature at the Inlet
52
Table 10: Lubricating Oil Temperature at the Outlet
52
Exhaust Gas Temperature before Turbine
53
Turbocharger Speed
54
Fig. 27: Layout and Overview of Speed Measurement System
54
Fig. 28: Replacing the Speed Sensor
56
Table 11: Tightening Torque (86505)
56
Operation and Service
57
Noise Emission
57
Fig. 29: Noise Insulation, Bellows
58
Service Work
59
Fig. 30: Replacing the Protective Grid
61
Expected Replacement Intervals
63
Table 12: Expected Replacement Intervals
63
Stopping the Engine
65
Periodic Maintenance Work
66
Foreword to Maintenance
66
Table 13: Maintenance Table
66
Cleaning the Compressor During Operation
67
Table 14: Parameters for Wet Cleaning of Compressor
69
Fig. 31: Carrying out Wet Cleaning of Compressor
69
Cleaning the Turbine During Operation
70
Table 15: Turbine Wet Cleaning, Recommended Operating State
72
Fig. 32: Carrying out Wet Cleaning of Turbine
73
Table 16: Wet Cleaning of Turbine, Parameters
73
Cleaning Components Mechanically
74
Fig. 33: Cleaning the Filter Silencer
75
Fig. 34: Compressor-End, Non-Rotating Parts
77
Fig. 35: Turbine End, Non-Rotating Parts
78
Fig. 36: Soaking the Turbine End
81
Table 17: Value Table for Soaking
81
Table 20: Malfunctions When Starting - Rubbing of Rotating Parts
84
Table 19: Malfunctions When Starting - Vibrations
84
Table 18: Malfunctions When Starting - Delayed Start-Up
84
Malfunctions When Starting
84
Eliminating Malfunctions
84
Malfunctions During Operation
85
Table 21: Malfunctions During Operation - Lubricating Oil Pressure too Low
85
Table 22: Malfunctions During Operation - Speed Reduces
85
Table 23: Malfunctions During Operation - Speed Increases
85
Table 24: Malfunctions During Operation - Exhaust Gas Temperature too High
86
Table 25: Malfunctions During Operation - Charge Air Pressure too Low
86
Table 26: Malfunctions During Operation - Charge Air Pressure too High
87
Table 27: Malfunctions During Operation - Engine Performance Losses
87
Turbocharger Is Surging
88
Table 28: Malfunction - Turbocharger Pumping
88
Table 29: Malfunction - Sporadic Surge Blows
88
Table 31: Malfunctions When Stopping - Runout Time too Short
89
Malfunctions When Stopping
89
Table 30: Malfunctions When Stopping - Runout Noises
89
Speed Measurement System
90
Table 32: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
90
Table 33: Malfunction of the Speed Measurement System - Measured Speed too High
90
Table 34: Malfunction of the Speed Measurement System - Measured Speed too Low
90
Dismantling and Fitting
91
Introduction
91
Material Required
92
Fig. 37: Swivel Lifting Eyes
92
Table 35: Swivel Lifting Eyes
92
Fig. 38: Starpoint Ring Nut VRM
93
ABB A135-M66 Operation Manual (152 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 19.21 MB
Table of Contents
Operation Manual / A130-M - A145-M
3
Table of Contents
3
Fig. 1: Serial Number (01) on the Rating Plate
6
Operation Manual / A130-M
6
Purpose of the Manual
6
Introduction
6
Contact Information
7
Essential Information
7
Layout and Function of the Turbocharger
8
Fig. 2: Layout and Function of the Turbocharger
8
Fig. 3: Compressor Wheel Cooling
9
Symbols, Definitions
10
Table 1: Definition of Pictograms
11
Storage of New Turbochargers and Spare Parts
12
Fig. 4: Volatile Corrosion Inhibitor (VCI)
12
Fig. 5: Package with Hygrometer
13
Registered Trademarks
14
CE Conformity
15
Safety
15
Introduction
15
Definition of Mandatory Signs
16
Definition of Safety Instructions
16
Table 2: Personal Protective Equipment to be Worn at All Times
16
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
16
Intended Use
17
Deflagration on Gas Engines
18
Warning Plates on the Turbocharger
19
Fig. 6: Warning Plate Locations
19
Turbocharger Rating Plate
20
Fig. 7: Rating Plate
20
Fig. 8: Locations of the Rating Plates
21
Periodic Check of the Pressure Vessels
22
Lifting of Loads
23
Fig. 9: Attachment of Loads on the Crane Hook
23
Fig. 10: Attachment Angle
23
Prerequisites for Operation and Maintenance
24
Hazards During Operation and Maintenance
25
Safe Operation
27
Fig. 11
27
Safe Maintenance
28
Removing and Installing
32
Turbocharger Weight and Transportation
32
Fig. 12: Suspension of Complete Turbocharger Unit
32
Table 4: Weight of Complete Turbocharger Unit
32
Fig. 13: Turbine Cleaning Nozzle
33
Removing the Turbocharger
33
Fig. 14: Removing the Turbocharger
34
Fig. 15: Loosening the Clamping Nut
36
Fig. 16: Turbocharger Centre of Gravity
37
Installing the Turbocharger
38
Fig. 17: Inserting Gaskets into the Bracket
38
Fig. 18: Inserting the Threaded Rods
39
Fig. 19: Requirements for Threaded Rods
39
Table 5: Requirements for Threaded Rods
39
Fig. 20: Placing the Turbocharger on the Bracket
40
Table 6: Tightening Torque for Standard Nuts
41
Fig. 21: Preparing the Clamping Nut for the Tightening Procedure
42
Fig. 22: Tightening Pressure Screws
43
Table 7: Torque-Controlled Tightening of the Pressure Screws
43
Fig. 23: Connecting the Speed Sensor
44
Fig. 24: Connecting the Compressor Cooling Air Intake
44
Fig. 25: Attaching the Support
45
Commissioning
46
Oil Supply
46
Fig. 26: Oil Orifice
47
Inspection Procedures
48
Commissioning after Taking out of Operation
50
Monitoring Operation
51
Oil Pressure, Oil Temperature
51
Table 8: Lubricating Oil Pressure at Oil Inlet before Turbocharger
51
Table 9: Lubricating Oil Temperature at the Inlet
52
Table 10: Lubricating Oil Temperature at the Outlet
52
Exhaust Gas Temperature before Turbine
53
Turbocharger Speed
54
Fig. 27: Layout and Overview of Speed Measurement System
54
Fig. 28: Replacing the Speed Sensor
56
Table 11: Tightening Torque (86505)
56
Operation and Service
57
Noise Emission
57
Fig. 29: Noise Insulation, Bellows
58
Service Work
59
Fig. 30: Replacing the Protective Grid
61
Expected Replacement Intervals
63
Table 12: Expected Replacement Intervals
63
Stopping the Engine
65
Periodic Maintenance Work
66
Foreword to Maintenance
66
Table 13: Maintenance Table
66
Cleaning the Compressor During Operation
67
Table 14: Parameters for Wet Cleaning of Compressor
69
Fig. 31: Carrying out Wet Cleaning of Compressor
69
Cleaning the Turbine During Operation
70
Table 15: Turbine Wet Cleaning, Recommended Operating State
72
Fig. 32: Carrying out Wet Cleaning of Turbine
73
Table 16: Wet Cleaning of Turbine, Parameters
73
Cleaning Components Mechanically
74
Fig. 33: Cleaning the Filter Silencer
75
Fig. 34: Compressor-End, Non-Rotating Parts
77
Fig. 35: Turbine End, Non-Rotating Parts
78
Fig. 36: Soaking the Turbine End
81
Table 17: Value Table for Soaking
81
Table 20: Malfunctions When Starting - Rubbing of Rotating Parts
84
Table 19: Malfunctions When Starting - Vibrations
84
Table 18: Malfunctions When Starting - Delayed Start-Up
84
Malfunctions When Starting
84
Eliminating Malfunctions
84
Malfunctions During Operation
85
Table 21: Malfunctions During Operation - Lubricating Oil Pressure too Low
85
Table 22: Malfunctions During Operation - Speed Reduces
85
Table 23: Malfunctions During Operation - Speed Increases
85
Table 24: Malfunctions During Operation - Exhaust Gas Temperature too High
86
Table 25: Malfunctions During Operation - Charge Air Pressure too Low
86
Table 26: Malfunctions During Operation - Charge Air Pressure too High
87
Table 27: Malfunctions During Operation - Engine Performance Losses
87
Turbocharger Is Surging
88
Table 28: Malfunction - Turbocharger Pumping
88
Table 29: Malfunction - Sporadic Surge Blows
88
Table 31: Malfunctions When Stopping - Runout Time too Short
89
Malfunctions When Stopping
89
Table 30: Malfunctions When Stopping - Runout Noises
89
Speed Measurement System
90
Table 32: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
90
Table 33: Malfunction of the Speed Measurement System - Measured Speed too High
90
Table 34: Malfunction of the Speed Measurement System - Measured Speed too Low
90
Dismantling and Fitting
91
Introduction
91
Material Required
92
Fig. 37: Swivel Lifting Eyes
92
Table 35: Swivel Lifting Eyes
92
Fig. 38: Starpoint Ring Nut VRM
93
ABB A135-M66 Operation Manual (152 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 19.21 MB
Table of Contents
Operation Manual / A130-M - A145-M
3
Table of Contents
3
Fig. 1: Serial Number (01) on the Rating Plate
6
Operation Manual / A130-M
6
Purpose of the Manual
6
Introduction
6
Contact Information
7
Essential Information
7
Layout and Function of the Turbocharger
8
Fig. 2: Layout and Function of the Turbocharger
8
Fig. 3: Compressor Wheel Cooling
9
Symbols, Definitions
10
Table 1: Definition of Pictograms
11
Storage of New Turbochargers and Spare Parts
12
Fig. 4: Volatile Corrosion Inhibitor (VCI)
12
Fig. 5: Package with Hygrometer
13
Registered Trademarks
14
CE Conformity
15
Safety
15
Introduction
15
Definition of Mandatory Signs
16
Definition of Safety Instructions
16
Table 2: Personal Protective Equipment to be Worn at All Times
16
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
16
Intended Use
17
Deflagration on Gas Engines
18
Warning Plates on the Turbocharger
19
Fig. 6: Warning Plate Locations
19
Turbocharger Rating Plate
20
Fig. 7: Rating Plate
20
Fig. 8: Locations of the Rating Plates
21
Periodic Check of the Pressure Vessels
22
Lifting of Loads
23
Fig. 9: Attachment of Loads on the Crane Hook
23
Fig. 10: Attachment Angle
23
Prerequisites for Operation and Maintenance
24
Hazards During Operation and Maintenance
25
Safe Operation
27
Fig. 11
27
Safe Maintenance
28
Removing and Installing
32
Turbocharger Weight and Transportation
32
Fig. 12: Suspension of Complete Turbocharger Unit
32
Table 4: Weight of Complete Turbocharger Unit
32
Fig. 13: Turbine Cleaning Nozzle
33
Removing the Turbocharger
33
Fig. 14: Removing the Turbocharger
34
Fig. 15: Loosening the Clamping Nut
36
Fig. 16: Turbocharger Centre of Gravity
37
Installing the Turbocharger
38
Fig. 17: Inserting Gaskets into the Bracket
38
Fig. 18: Inserting the Threaded Rods
39
Fig. 19: Requirements for Threaded Rods
39
Table 5: Requirements for Threaded Rods
39
Fig. 20: Placing the Turbocharger on the Bracket
40
Table 6: Tightening Torque for Standard Nuts
41
Fig. 21: Preparing the Clamping Nut for the Tightening Procedure
42
Fig. 22: Tightening Pressure Screws
43
Table 7: Torque-Controlled Tightening of the Pressure Screws
43
Fig. 23: Connecting the Speed Sensor
44
Fig. 24: Connecting the Compressor Cooling Air Intake
44
Fig. 25: Attaching the Support
45
Commissioning
46
Oil Supply
46
Fig. 26: Oil Orifice
47
Inspection Procedures
48
Commissioning after Taking out of Operation
50
Monitoring Operation
51
Oil Pressure, Oil Temperature
51
Table 8: Lubricating Oil Pressure at Oil Inlet before Turbocharger
51
Table 9: Lubricating Oil Temperature at the Inlet
52
Table 10: Lubricating Oil Temperature at the Outlet
52
Exhaust Gas Temperature before Turbine
53
Turbocharger Speed
54
Fig. 27: Layout and Overview of Speed Measurement System
54
Fig. 28: Replacing the Speed Sensor
56
Table 11: Tightening Torque (86505)
56
Operation and Service
57
Noise Emission
57
Fig. 29: Noise Insulation, Bellows
58
Service Work
59
Fig. 30: Replacing the Protective Grid
61
Expected Replacement Intervals
63
Table 12: Expected Replacement Intervals
63
Stopping the Engine
65
Periodic Maintenance Work
66
Foreword to Maintenance
66
Table 13: Maintenance Table
66
Cleaning the Compressor During Operation
67
Table 14: Parameters for Wet Cleaning of Compressor
69
Fig. 31: Carrying out Wet Cleaning of Compressor
69
Cleaning the Turbine During Operation
70
Table 15: Turbine Wet Cleaning, Recommended Operating State
72
Fig. 32: Carrying out Wet Cleaning of Turbine
73
Table 16: Wet Cleaning of Turbine, Parameters
73
Cleaning Components Mechanically
74
Fig. 33: Cleaning the Filter Silencer
75
Fig. 34: Compressor-End, Non-Rotating Parts
77
Fig. 35: Turbine End, Non-Rotating Parts
78
Fig. 36: Soaking the Turbine End
81
Table 17: Value Table for Soaking
81
Table 20: Malfunctions When Starting - Rubbing of Rotating Parts
84
Table 19: Malfunctions When Starting - Vibrations
84
Table 18: Malfunctions When Starting - Delayed Start-Up
84
Malfunctions When Starting
84
Eliminating Malfunctions
84
Malfunctions During Operation
85
Table 21: Malfunctions During Operation - Lubricating Oil Pressure too Low
85
Table 22: Malfunctions During Operation - Speed Reduces
85
Table 23: Malfunctions During Operation - Speed Increases
85
Table 24: Malfunctions During Operation - Exhaust Gas Temperature too High
86
Table 25: Malfunctions During Operation - Charge Air Pressure too Low
86
Table 26: Malfunctions During Operation - Charge Air Pressure too High
87
Table 27: Malfunctions During Operation - Engine Performance Losses
87
Turbocharger Is Surging
88
Table 28: Malfunction - Turbocharger Pumping
88
Table 29: Malfunction - Sporadic Surge Blows
88
Table 31: Malfunctions When Stopping - Runout Time too Short
89
Malfunctions When Stopping
89
Table 30: Malfunctions When Stopping - Runout Noises
89
Speed Measurement System
90
Table 32: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
90
Table 33: Malfunction of the Speed Measurement System - Measured Speed too High
90
Table 34: Malfunction of the Speed Measurement System - Measured Speed too Low
90
Dismantling and Fitting
91
Introduction
91
Material Required
92
Fig. 37: Swivel Lifting Eyes
92
Table 35: Swivel Lifting Eyes
92
Fig. 38: Starpoint Ring Nut VRM
93
ABB A135-M66 Operation Manual (152 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 19.21 MB
Table of Contents
Operation Manual / A130-M - A145-M
3
Table of Contents
3
Fig. 1: Serial Number (01) on the Rating Plate
6
Operation Manual / A130-M
6
Purpose of the Manual
6
Introduction
6
Contact Information
7
Essential Information
7
Layout and Function of the Turbocharger
8
Fig. 2: Layout and Function of the Turbocharger
8
Fig. 3: Compressor Wheel Cooling
9
Symbols, Definitions
10
Table 1: Definition of Pictograms
11
Storage of New Turbochargers and Spare Parts
12
Fig. 4: Volatile Corrosion Inhibitor (VCI)
12
Fig. 5: Package with Hygrometer
13
Registered Trademarks
14
CE Conformity
15
Safety
15
Introduction
15
Definition of Mandatory Signs
16
Definition of Safety Instructions
16
Table 2: Personal Protective Equipment to be Worn at All Times
16
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
16
Intended Use
17
Deflagration on Gas Engines
18
Warning Plates on the Turbocharger
19
Fig. 6: Warning Plate Locations
19
Turbocharger Rating Plate
20
Fig. 7: Rating Plate
20
Fig. 8: Locations of the Rating Plates
21
Periodic Check of the Pressure Vessels
22
Lifting of Loads
23
Fig. 9: Attachment of Loads on the Crane Hook
23
Fig. 10: Attachment Angle
23
Prerequisites for Operation and Maintenance
24
Hazards During Operation and Maintenance
25
Safe Operation
27
Fig. 11
27
Safe Maintenance
28
Removing and Installing
32
Turbocharger Weight and Transportation
32
Fig. 12: Suspension of Complete Turbocharger Unit
32
Table 4: Weight of Complete Turbocharger Unit
32
Fig. 13: Turbine Cleaning Nozzle
33
Removing the Turbocharger
33
Fig. 14: Removing the Turbocharger
34
Fig. 15: Loosening the Clamping Nut
36
Fig. 16: Turbocharger Centre of Gravity
37
Installing the Turbocharger
38
Fig. 17: Inserting Gaskets into the Bracket
38
Fig. 18: Inserting the Threaded Rods
39
Fig. 19: Requirements for Threaded Rods
39
Table 5: Requirements for Threaded Rods
39
Fig. 20: Placing the Turbocharger on the Bracket
40
Table 6: Tightening Torque for Standard Nuts
41
Fig. 21: Preparing the Clamping Nut for the Tightening Procedure
42
Fig. 22: Tightening Pressure Screws
43
Table 7: Torque-Controlled Tightening of the Pressure Screws
43
Fig. 23: Connecting the Speed Sensor
44
Fig. 24: Connecting the Compressor Cooling Air Intake
44
Fig. 25: Attaching the Support
45
Commissioning
46
Oil Supply
46
Fig. 26: Oil Orifice
47
Inspection Procedures
48
Commissioning after Taking out of Operation
50
Monitoring Operation
51
Oil Pressure, Oil Temperature
51
Table 8: Lubricating Oil Pressure at Oil Inlet before Turbocharger
51
Table 9: Lubricating Oil Temperature at the Inlet
52
Table 10: Lubricating Oil Temperature at the Outlet
52
Exhaust Gas Temperature before Turbine
53
Turbocharger Speed
54
Fig. 27: Layout and Overview of Speed Measurement System
54
Fig. 28: Replacing the Speed Sensor
56
Table 11: Tightening Torque (86505)
56
Operation and Service
57
Noise Emission
57
Fig. 29: Noise Insulation, Bellows
58
Service Work
59
Fig. 30: Replacing the Protective Grid
61
Expected Replacement Intervals
63
Table 12: Expected Replacement Intervals
63
Stopping the Engine
65
Periodic Maintenance Work
66
Foreword to Maintenance
66
Table 13: Maintenance Table
66
Cleaning the Compressor During Operation
67
Table 14: Parameters for Wet Cleaning of Compressor
69
Fig. 31: Carrying out Wet Cleaning of Compressor
69
Cleaning the Turbine During Operation
70
Table 15: Turbine Wet Cleaning, Recommended Operating State
72
Fig. 32: Carrying out Wet Cleaning of Turbine
73
Table 16: Wet Cleaning of Turbine, Parameters
73
Cleaning Components Mechanically
74
Fig. 33: Cleaning the Filter Silencer
75
Fig. 34: Compressor-End, Non-Rotating Parts
77
Fig. 35: Turbine End, Non-Rotating Parts
78
Fig. 36: Soaking the Turbine End
81
Table 17: Value Table for Soaking
81
Table 20: Malfunctions When Starting - Rubbing of Rotating Parts
84
Table 19: Malfunctions When Starting - Vibrations
84
Table 18: Malfunctions When Starting - Delayed Start-Up
84
Malfunctions When Starting
84
Eliminating Malfunctions
84
Malfunctions During Operation
85
Table 21: Malfunctions During Operation - Lubricating Oil Pressure too Low
85
Table 22: Malfunctions During Operation - Speed Reduces
85
Table 23: Malfunctions During Operation - Speed Increases
85
Table 24: Malfunctions During Operation - Exhaust Gas Temperature too High
86
Table 25: Malfunctions During Operation - Charge Air Pressure too Low
86
Table 26: Malfunctions During Operation - Charge Air Pressure too High
87
Table 27: Malfunctions During Operation - Engine Performance Losses
87
Turbocharger Is Surging
88
Table 28: Malfunction - Turbocharger Pumping
88
Table 29: Malfunction - Sporadic Surge Blows
88
Table 31: Malfunctions When Stopping - Runout Time too Short
89
Malfunctions When Stopping
89
Table 30: Malfunctions When Stopping - Runout Noises
89
Speed Measurement System
90
Table 32: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
90
Table 33: Malfunction of the Speed Measurement System - Measured Speed too High
90
Table 34: Malfunction of the Speed Measurement System - Measured Speed too Low
90
Dismantling and Fitting
91
Introduction
91
Material Required
92
Fig. 37: Swivel Lifting Eyes
92
Table 35: Swivel Lifting Eyes
92
Fig. 38: Starpoint Ring Nut VRM
93
ABB A135-M66 Operation Manual (152 pages)
Turbocharging
Brand:
ABB
| Category:
Industrial Equipment
| Size: 19.21 MB
Table of Contents
Table of Contents
3
1 Introduction
6
Operation Manual / A130-M
6
Purpose of the Manual
6
Fig. 1: Serial Number (01) on the Rating Plate
6
Contact Information
7
Essential Information
7
Layout and Function of the Turbocharger
8
Fig. 2: Layout and Function of the Turbocharger
8
Fig. 3: Compressor Wheel Cooling
9
Symbols, Definitions
10
Table 1: Definition of Pictograms
11
Storage of New Turbochargers and Spare Parts
12
Fig. 4: Volatile Corrosion Inhibitor (VCI)
12
Fig. 5: Package with Hygrometer
13
Registered Trademarks
14
CE Conformity
15
Introduction
15
2 Safety
15
Definition of Mandatory Signs
16
Definition of Safety Instructions
16
Table 2: Personal Protective Equipment to be Worn at All Times
16
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
16
Intended Use
17
Deflagration on Gas Engines
18
Warning Plates on the Turbocharger
19
Fig. 6: Warning Plate Locations
19
Turbocharger Rating Plate
20
Fig. 7: Rating Plate
20
Fig. 8: Locations of the Rating Plates
21
Periodic Check of the Pressure Vessels
22
Lifting of Loads
23
Fig. 9: Attachment of Loads on the Crane Hook
23
Fig. 10: Attachment Angle
23
Prerequisites for Operation and Maintenance
24
Hazards During Operation and Maintenance
25
Safe Operation
27
Fig. 11
27
Safe Maintenance
28
3 Removing and Installing
32
Turbocharger Weight and Transportation
32
Fig. 12: Suspension of Complete Turbocharger Unit
32
Table 4: Weight of Complete Turbocharger Unit
32
Removing the Turbocharger
33
Fig. 13: Turbine Cleaning Nozzle
33
Fig. 14: Removing the Turbocharger
34
Fig. 15: Loosening the Clamping Nut
36
Fig. 16: Turbocharger Centre of Gravity
37
Installing the Turbocharger
38
Fig. 17: Inserting Gaskets into the Bracket
38
Fig. 18: Inserting the Threaded Rods
39
Fig. 19: Requirements for Threaded Rods
39
Table 5: Requirements for Threaded Rods
39
Fig. 20: Placing the Turbocharger on the Bracket
40
Table 6: Tightening Torque for Standard Nuts
41
Fig. 21: Preparing the Clamping Nut for the Tightening Procedure
42
Fig. 22: Tightening Pressure Screws
43
Table 7: Torque-Controlled Tightening of the Pressure Screws
43
Fig. 23: Connecting the Speed Sensor
44
Fig. 24: Connecting the Compressor Cooling Air Intake
44
Fig. 25: Attaching the Support
45
4 Commissioning
46
Oil Supply
46
Fig. 26: Oil Orifice
47
Inspection Procedures
48
Commissioning after Taking out of Operation
50
5 Monitoring Operation
51
Oil Pressure, Oil Temperature
51
Table 8: Lubricating Oil Pressure at Oil Inlet before Turbocharger
51
Table 10: Lubricating Oil Temperature at the Outlet
52
Table 9: Lubricating Oil Temperature at the Inlet
52
Exhaust Gas Temperature before Turbine
53
Turbocharger Speed
54
Fig. 27: Layout and Overview of Speed Measurement System
54
Fig. 28: Replacing the Speed Sensor
56
Table 11: Tightening Torque (86505)
56
Noise Emission
57
Fig. 29: Noise Insulation, Bellows
58
6 Operation and Service
57
Service Work
59
Fig. 30: Replacing the Protective Grid
61
Expected Replacement Intervals
63
Table 12: Expected Replacement Intervals
63
Stopping the Engine
65
Foreword to Maintenance
66
7 Periodic Maintenance Work
66
Table 13: Maintenance Table
66
Cleaning the Compressor During Operation
67
Fig. 31: Carrying out Wet Cleaning of Compressor
69
Table 14: Parameters for Wet Cleaning of Compressor
69
Cleaning the Turbine During Operation
70
Table 15: Turbine Wet Cleaning, Recommended Operating State
72
Fig. 32: Carrying out Wet Cleaning of Turbine
73
Table 16: Wet Cleaning of Turbine, Parameters
73
Cleaning Components Mechanically
74
Fig. 33: Cleaning the Filter Silencer
75
Fig. 34: Compressor-End, Non-Rotating Parts
77
Fig. 35: Turbine End, Non-Rotating Parts
78
Fig. 36: Soaking the Turbine End
81
Table 17: Value Table for Soaking
81
8 Eliminating Malfunctions
84
Malfunctions When Starting
84
Table 18: Malfunctions When Starting - Delayed Start-Up
84
Table 19: Malfunctions When Starting - Vibrations
84
Table 20: Malfunctions When Starting - Rubbing of Rotating Parts
84
Malfunctions During Operation
85
Table 21: Malfunctions During Operation - Lubricating Oil Pressure too Low
85
Table 22: Malfunctions During Operation - Speed Reduces
85
Table 23: Malfunctions During Operation - Speed Increases
85
Table 24: Malfunctions During Operation - Exhaust Gas Temperature too High
86
Table 25: Malfunctions During Operation - Charge Air Pressure too Low
86
Table 26: Malfunctions During Operation - Charge Air Pressure too High
87
Table 27: Malfunctions During Operation - Engine Performance Losses
87
Table 28: Malfunction - Turbocharger Pumping
88
Table 29: Malfunction - Sporadic Surge Blows
88
Turbocharger Is Surging
88
Malfunctions When Stopping
89
Table 30: Malfunctions When Stopping - Runout Noises
89
Table 31: Malfunctions When Stopping - Runout Time too Short
89
Speed Measurement System
90
Table 32: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
90
Table 33: Malfunction of the Speed Measurement System - Measured Speed too High
90
Table 34: Malfunction of the Speed Measurement System - Measured Speed too Low
90
9 Dismantling and Fitting
91
Introduction
91
Material Required
92
Fig. 37: Swivel Lifting Eyes
92
Table 35: Swivel Lifting Eyes
92
Fig. 38: Starpoint Ring Nut VRM
93
ABB A135-M66 Operation Manual (152 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 19.21 MB
Table of Contents
Operation Manual / A130-M - A145-M
3
Table of Contents
3
Fig. 1: Serial Number (01) on the Rating Plate
6
Operation Manual / A130-M
6
Purpose of the Manual
6
Introduction
6
Contact Information
7
Essential Information
7
Layout and Function of the Turbocharger
8
Fig. 2: Layout and Function of the Turbocharger
8
Fig. 3: Compressor Wheel Cooling
9
Symbols, Definitions
10
Table 1: Definition of Pictograms
11
Storage of New Turbochargers and Spare Parts
12
Fig. 4: Volatile Corrosion Inhibitor (VCI)
12
Fig. 5: Package with Hygrometer
13
Registered Trademarks
14
CE Conformity
15
Safety
15
Introduction
15
Definition of Mandatory Signs
16
Definition of Safety Instructions
16
Table 2: Personal Protective Equipment to be Worn at All Times
16
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
16
Intended Use
17
Deflagration on Gas Engines
18
Warning Plates on the Turbocharger
19
Fig. 6: Warning Plate Locations
19
Turbocharger Rating Plate
20
Fig. 7: Rating Plate
20
Fig. 8: Locations of the Rating Plates
21
Periodic Check of the Pressure Vessels
22
Lifting of Loads
23
Fig. 9: Attachment of Loads on the Crane Hook
23
Fig. 10: Attachment Angle
23
Prerequisites for Operation and Maintenance
24
Hazards During Operation and Maintenance
25
Safe Operation
27
Fig. 11
27
Safe Maintenance
28
Removing and Installing
32
Turbocharger Weight and Transportation
32
Fig. 12: Suspension of Complete Turbocharger Unit
32
Table 4: Weight of Complete Turbocharger Unit
32
Fig. 13: Turbine Cleaning Nozzle
33
Removing the Turbocharger
33
Fig. 14: Removing the Turbocharger
34
Fig. 15: Loosening the Clamping Nut
36
Fig. 16: Turbocharger Centre of Gravity
37
Installing the Turbocharger
38
Fig. 17: Inserting Gaskets into the Bracket
38
Fig. 18: Inserting the Threaded Rods
39
Fig. 19: Requirements for Threaded Rods
39
Table 5: Requirements for Threaded Rods
39
Fig. 20: Placing the Turbocharger on the Bracket
40
Table 6: Tightening Torque for Standard Nuts
41
Fig. 21: Preparing the Clamping Nut for the Tightening Procedure
42
Fig. 22: Tightening Pressure Screws
43
Table 7: Torque-Controlled Tightening of the Pressure Screws
43
Fig. 23: Connecting the Speed Sensor
44
Fig. 24: Connecting the Compressor Cooling Air Intake
44
Fig. 25: Attaching the Support
45
Commissioning
46
Oil Supply
46
Fig. 26: Oil Orifice
47
Inspection Procedures
48
Commissioning after Taking out of Operation
50
Monitoring Operation
51
Oil Pressure, Oil Temperature
51
Table 8: Lubricating Oil Pressure at Oil Inlet before Turbocharger
51
Table 9: Lubricating Oil Temperature at the Inlet
52
Table 10: Lubricating Oil Temperature at the Outlet
52
Exhaust Gas Temperature before Turbine
53
Turbocharger Speed
54
Fig. 27: Layout and Overview of Speed Measurement System
54
Fig. 28: Replacing the Speed Sensor
56
Table 11: Tightening Torque (86505)
56
Operation and Service
57
Noise Emission
57
Fig. 29: Noise Insulation, Bellows
58
Service Work
59
Fig. 30: Replacing the Protective Grid
61
Expected Replacement Intervals
63
Table 12: Expected Replacement Intervals
63
Stopping the Engine
65
Periodic Maintenance Work
66
Foreword to Maintenance
66
Table 13: Maintenance Table
66
Cleaning the Compressor During Operation
67
Table 14: Parameters for Wet Cleaning of Compressor
69
Fig. 31: Carrying out Wet Cleaning of Compressor
69
Cleaning the Turbine During Operation
70
Table 15: Turbine Wet Cleaning, Recommended Operating State
72
Fig. 32: Carrying out Wet Cleaning of Turbine
73
Table 16: Wet Cleaning of Turbine, Parameters
73
Cleaning Components Mechanically
74
Fig. 33: Cleaning the Filter Silencer
75
Fig. 34: Compressor-End, Non-Rotating Parts
77
Fig. 35: Turbine End, Non-Rotating Parts
78
Fig. 36: Soaking the Turbine End
81
Table 17: Value Table for Soaking
81
Table 20: Malfunctions When Starting - Rubbing of Rotating Parts
84
Table 19: Malfunctions When Starting - Vibrations
84
Table 18: Malfunctions When Starting - Delayed Start-Up
84
Malfunctions When Starting
84
Eliminating Malfunctions
84
Malfunctions During Operation
85
Table 21: Malfunctions During Operation - Lubricating Oil Pressure too Low
85
Table 22: Malfunctions During Operation - Speed Reduces
85
Table 23: Malfunctions During Operation - Speed Increases
85
Table 24: Malfunctions During Operation - Exhaust Gas Temperature too High
86
Table 25: Malfunctions During Operation - Charge Air Pressure too Low
86
Table 26: Malfunctions During Operation - Charge Air Pressure too High
87
Table 27: Malfunctions During Operation - Engine Performance Losses
87
Turbocharger Is Surging
88
Table 28: Malfunction - Turbocharger Pumping
88
Table 29: Malfunction - Sporadic Surge Blows
88
Table 31: Malfunctions When Stopping - Runout Time too Short
89
Malfunctions When Stopping
89
Table 30: Malfunctions When Stopping - Runout Noises
89
Speed Measurement System
90
Table 32: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
90
Table 33: Malfunction of the Speed Measurement System - Measured Speed too High
90
Table 34: Malfunction of the Speed Measurement System - Measured Speed too Low
90
Dismantling and Fitting
91
Introduction
91
Material Required
92
Fig. 37: Swivel Lifting Eyes
92
Table 35: Swivel Lifting Eyes
92
Fig. 38: Starpoint Ring Nut VRM
93
ABB A135-M66 Operation Manual (152 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 19.21 MB
Table of Contents
Operation Manual / A130-M - A145-M
3
Table of Contents
3
Fig. 1: Serial Number (01) on the Rating Plate
6
Operation Manual / A130-M
6
Purpose of the Manual
6
Introduction
6
Contact Information
7
Essential Information
7
Layout and Function of the Turbocharger
8
Fig. 2: Layout and Function of the Turbocharger
8
Fig. 3: Compressor Wheel Cooling
9
Symbols, Definitions
10
Table 1: Definition of Pictograms
11
Storage of New Turbochargers and Spare Parts
12
Fig. 4: Volatile Corrosion Inhibitor (VCI)
12
Fig. 5: Package with Hygrometer
13
Registered Trademarks
14
CE Conformity
15
Safety
15
Introduction
15
Definition of Mandatory Signs
16
Definition of Safety Instructions
16
Table 2: Personal Protective Equipment to be Worn at All Times
16
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
16
Intended Use
17
Deflagration on Gas Engines
18
Warning Plates on the Turbocharger
19
Fig. 6: Warning Plate Locations
19
Turbocharger Rating Plate
20
Fig. 7: Rating Plate
20
Fig. 8: Locations of the Rating Plates
21
Periodic Check of the Pressure Vessels
22
Lifting of Loads
23
Fig. 9: Attachment of Loads on the Crane Hook
23
Fig. 10: Attachment Angle
23
Prerequisites for Operation and Maintenance
24
Hazards During Operation and Maintenance
25
Safe Operation
27
Fig. 11
27
Safe Maintenance
28
Removing and Installing
32
Turbocharger Weight and Transportation
32
Fig. 12: Suspension of Complete Turbocharger Unit
32
Table 4: Weight of Complete Turbocharger Unit
32
Fig. 13: Turbine Cleaning Nozzle
33
Removing the Turbocharger
33
Fig. 14: Removing the Turbocharger
34
Fig. 15: Loosening the Clamping Nut
36
Fig. 16: Turbocharger Centre of Gravity
37
Installing the Turbocharger
38
Fig. 17: Inserting Gaskets into the Bracket
38
Fig. 18: Inserting the Threaded Rods
39
Fig. 19: Requirements for Threaded Rods
39
Table 5: Requirements for Threaded Rods
39
Fig. 20: Placing the Turbocharger on the Bracket
40
Table 6: Tightening Torque for Standard Nuts
41
Fig. 21: Preparing the Clamping Nut for the Tightening Procedure
42
Fig. 22: Tightening Pressure Screws
43
Table 7: Torque-Controlled Tightening of the Pressure Screws
43
Fig. 23: Connecting the Speed Sensor
44
Fig. 24: Connecting the Compressor Cooling Air Intake
44
Fig. 25: Attaching the Support
45
Commissioning
46
Oil Supply
46
Fig. 26: Oil Orifice
47
Inspection Procedures
48
Commissioning after Taking out of Operation
50
Monitoring Operation
51
Oil Pressure, Oil Temperature
51
Table 8: Lubricating Oil Pressure at Oil Inlet before Turbocharger
51
Table 9: Lubricating Oil Temperature at the Inlet
52
Table 10: Lubricating Oil Temperature at the Outlet
52
Exhaust Gas Temperature before Turbine
53
Turbocharger Speed
54
Fig. 27: Layout and Overview of Speed Measurement System
54
Fig. 28: Replacing the Speed Sensor
56
Table 11: Tightening Torque (86505)
56
Operation and Service
57
Noise Emission
57
Fig. 29: Noise Insulation, Bellows
58
Service Work
59
Fig. 30: Replacing the Protective Grid
61
Expected Replacement Intervals
63
Table 12: Expected Replacement Intervals
63
Stopping the Engine
65
Periodic Maintenance Work
66
Foreword to Maintenance
66
Table 13: Maintenance Table
66
Cleaning the Compressor During Operation
67
Table 14: Parameters for Wet Cleaning of Compressor
69
Fig. 31: Carrying out Wet Cleaning of Compressor
69
Cleaning the Turbine During Operation
70
Table 15: Turbine Wet Cleaning, Recommended Operating State
72
Fig. 32: Carrying out Wet Cleaning of Turbine
73
Table 16: Wet Cleaning of Turbine, Parameters
73
Cleaning Components Mechanically
74
Fig. 33: Cleaning the Filter Silencer
75
Fig. 34: Compressor-End, Non-Rotating Parts
77
Fig. 35: Turbine End, Non-Rotating Parts
78
Fig. 36: Soaking the Turbine End
81
Table 17: Value Table for Soaking
81
Table 20: Malfunctions When Starting - Rubbing of Rotating Parts
84
Table 19: Malfunctions When Starting - Vibrations
84
Table 18: Malfunctions When Starting - Delayed Start-Up
84
Malfunctions When Starting
84
Eliminating Malfunctions
84
Malfunctions During Operation
85
Table 21: Malfunctions During Operation - Lubricating Oil Pressure too Low
85
Table 22: Malfunctions During Operation - Speed Reduces
85
Table 23: Malfunctions During Operation - Speed Increases
85
Table 24: Malfunctions During Operation - Exhaust Gas Temperature too High
86
Table 25: Malfunctions During Operation - Charge Air Pressure too Low
86
Table 26: Malfunctions During Operation - Charge Air Pressure too High
87
Table 27: Malfunctions During Operation - Engine Performance Losses
87
Turbocharger Is Surging
88
Table 28: Malfunction - Turbocharger Pumping
88
Table 29: Malfunction - Sporadic Surge Blows
88
Table 31: Malfunctions When Stopping - Runout Time too Short
89
Malfunctions When Stopping
89
Table 30: Malfunctions When Stopping - Runout Noises
89
Speed Measurement System
90
Table 32: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
90
Table 33: Malfunction of the Speed Measurement System - Measured Speed too High
90
Table 34: Malfunction of the Speed Measurement System - Measured Speed too Low
90
Dismantling and Fitting
91
Introduction
91
Material Required
92
Fig. 37: Swivel Lifting Eyes
92
Table 35: Swivel Lifting Eyes
92
Fig. 38: Starpoint Ring Nut VRM
93
ABB A135-M66 Operation Manual (152 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 19.21 MB
Table of Contents
Operation Manual / A130-M - A145-M
3
Table of Contents
3
Fig. 1: Serial Number (01) on the Rating Plate
6
Operation Manual / A130-M
6
Purpose of the Manual
6
Introduction
6
Contact Information
7
Essential Information
7
Layout and Function of the Turbocharger
8
Fig. 2: Layout and Function of the Turbocharger
8
Fig. 3: Compressor Wheel Cooling
9
Symbols, Definitions
10
Table 1: Definition of Pictograms
11
Storage of New Turbochargers and Spare Parts
12
Fig. 4: Volatile Corrosion Inhibitor (VCI)
12
Fig. 5: Package with Hygrometer
13
Registered Trademarks
14
CE Conformity
15
Safety
15
Introduction
15
Definition of Mandatory Signs
16
Definition of Safety Instructions
16
Table 2: Personal Protective Equipment to be Worn at All Times
16
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
16
Intended Use
17
Deflagration on Gas Engines
18
Warning Plates on the Turbocharger
19
Fig. 6: Warning Plate Locations
19
Turbocharger Rating Plate
20
Fig. 7: Rating Plate
20
Fig. 8: Locations of the Rating Plates
21
Periodic Check of the Pressure Vessels
22
Lifting of Loads
23
Fig. 9: Attachment of Loads on the Crane Hook
23
Fig. 10: Attachment Angle
23
Prerequisites for Operation and Maintenance
24
Hazards During Operation and Maintenance
25
Safe Operation
27
Fig. 11
27
Safe Maintenance
28
Removing and Installing
32
Turbocharger Weight and Transportation
32
Fig. 12: Suspension of Complete Turbocharger Unit
32
Table 4: Weight of Complete Turbocharger Unit
32
Fig. 13: Turbine Cleaning Nozzle
33
Removing the Turbocharger
33
Fig. 14: Removing the Turbocharger
34
Fig. 15: Loosening the Clamping Nut
36
Fig. 16: Turbocharger Centre of Gravity
37
Installing the Turbocharger
38
Fig. 17: Inserting Gaskets into the Bracket
38
Fig. 18: Inserting the Threaded Rods
39
Fig. 19: Requirements for Threaded Rods
39
Table 5: Requirements for Threaded Rods
39
Fig. 20: Placing the Turbocharger on the Bracket
40
Table 6: Tightening Torque for Standard Nuts
41
Fig. 21: Preparing the Clamping Nut for the Tightening Procedure
42
Fig. 22: Tightening Pressure Screws
43
Table 7: Torque-Controlled Tightening of the Pressure Screws
43
Fig. 23: Connecting the Speed Sensor
44
Fig. 24: Connecting the Compressor Cooling Air Intake
44
Fig. 25: Attaching the Support
45
Commissioning
46
Oil Supply
46
Fig. 26: Oil Orifice
47
Inspection Procedures
48
Commissioning after Taking out of Operation
50
Monitoring Operation
51
Oil Pressure, Oil Temperature
51
Table 8: Lubricating Oil Pressure at Oil Inlet before Turbocharger
51
Table 9: Lubricating Oil Temperature at the Inlet
52
Table 10: Lubricating Oil Temperature at the Outlet
52
Exhaust Gas Temperature before Turbine
53
Turbocharger Speed
54
Fig. 27: Layout and Overview of Speed Measurement System
54
Fig. 28: Replacing the Speed Sensor
56
Table 11: Tightening Torque (86505)
56
Operation and Service
57
Noise Emission
57
Fig. 29: Noise Insulation, Bellows
58
Service Work
59
Fig. 30: Replacing the Protective Grid
61
Expected Replacement Intervals
63
Table 12: Expected Replacement Intervals
63
Stopping the Engine
65
Periodic Maintenance Work
66
Foreword to Maintenance
66
Table 13: Maintenance Table
66
Cleaning the Compressor During Operation
67
Table 14: Parameters for Wet Cleaning of Compressor
69
Fig. 31: Carrying out Wet Cleaning of Compressor
69
Cleaning the Turbine During Operation
70
Table 15: Turbine Wet Cleaning, Recommended Operating State
72
Fig. 32: Carrying out Wet Cleaning of Turbine
73
Table 16: Wet Cleaning of Turbine, Parameters
73
Cleaning Components Mechanically
74
Fig. 33: Cleaning the Filter Silencer
75
Fig. 34: Compressor-End, Non-Rotating Parts
77
Fig. 35: Turbine End, Non-Rotating Parts
78
Fig. 36: Soaking the Turbine End
81
Table 17: Value Table for Soaking
81
Table 20: Malfunctions When Starting - Rubbing of Rotating Parts
84
Table 19: Malfunctions When Starting - Vibrations
84
Table 18: Malfunctions When Starting - Delayed Start-Up
84
Malfunctions When Starting
84
Eliminating Malfunctions
84
Malfunctions During Operation
85
Table 21: Malfunctions During Operation - Lubricating Oil Pressure too Low
85
Table 22: Malfunctions During Operation - Speed Reduces
85
Table 23: Malfunctions During Operation - Speed Increases
85
Table 24: Malfunctions During Operation - Exhaust Gas Temperature too High
86
Table 25: Malfunctions During Operation - Charge Air Pressure too Low
86
Table 26: Malfunctions During Operation - Charge Air Pressure too High
87
Table 27: Malfunctions During Operation - Engine Performance Losses
87
Turbocharger Is Surging
88
Table 28: Malfunction - Turbocharger Pumping
88
Table 29: Malfunction - Sporadic Surge Blows
88
Table 31: Malfunctions When Stopping - Runout Time too Short
89
Malfunctions When Stopping
89
Table 30: Malfunctions When Stopping - Runout Noises
89
Speed Measurement System
90
Table 32: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
90
Table 33: Malfunction of the Speed Measurement System - Measured Speed too High
90
Table 34: Malfunction of the Speed Measurement System - Measured Speed too Low
90
Dismantling and Fitting
91
Introduction
91
Material Required
92
Fig. 37: Swivel Lifting Eyes
92
Table 35: Swivel Lifting Eyes
92
Fig. 38: Starpoint Ring Nut VRM
93
ABB A135-M66 Operation Manual (152 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 19.31 MB
Table of Contents
Operation Manual / A130-M - A145-M
3
Table of Contents
3
Fig. 1: Serial Number (01) on the Rating Plate
6
Operation Manual / A130-M
6
Purpose of the Manual
6
Introduction
6
Contact Information
7
Essential Information
7
Layout and Function of the Turbocharger
8
Fig. 2: Layout and Function of the Turbocharger
8
Fig. 3: Compressor Wheel Cooling
9
Symbols, Definitions
10
Table 1: Definition of Pictograms
11
Storage of New Turbochargers and Spare Parts
12
Fig. 4: Volatile Corrosion Inhibitor (VCI)
12
Fig. 5: Package with Hygrometer
13
Registered Trademarks
14
CE Conformity
15
Safety
15
Introduction
15
Definition of Mandatory Signs
16
Definition of Safety Instructions
16
Table 2: Personal Protective Equipment to be Worn at All Times
16
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
16
Intended Use
17
Deflagration on Gas Engines
18
Warning Plates on the Turbocharger
19
Fig. 6: Warning Plate Locations
19
Turbocharger Rating Plate
20
Fig. 7: Rating Plate
20
Fig. 8: Locations of the Rating Plates
21
Periodic Check of the Pressure Vessels
21
Lifting of Loads
23
Fig. 9: Attachment of Loads on the Crane Hook
23
Fig. 10: Attachment Angle
23
Prerequisites for Operation and Maintenance
24
Hazards During Operation and Maintenance
25
Safe Operation
26
Fig. 11
27
Safe Maintenance
28
Removing and Installing
32
Turbocharger Weight and Transportation
32
Fig. 12: Suspension of Complete Turbocharger Unit
32
Table 4: Weight of Complete Turbocharger Unit
32
Fig. 13: Turbine Cleaning Nozzle
33
Removing the Turbocharger
33
Fig. 14: Removing the Turbocharger
34
Fig. 15: Loosening the Clamping Nut
36
Fig. 16: Turbocharger Centre of Gravity
37
Installing the Turbocharger
38
Fig. 17: Inserting Gaskets into the Bracket
38
Fig. 18: Inserting the Threaded Rods
39
Fig. 19: Requirements for Threaded Rods
39
Table 5: Requirements for Threaded Rods
39
Fig. 20: Placing the Turbocharger on the Bracket
40
Table 6: Tightening Torque for Standard Nuts
41
Fig. 21: Preparing the Clamping Nut for the Tightening Procedure
42
Fig. 22: Tightening Pressure Screws
43
Table 7: Torque-Controlled Tightening of the Pressure Screws
43
Fig. 23: Connecting the Speed Sensor
44
Fig. 24: Connecting the Compressor Cooling Air Intake
44
Fig. 25: Attaching the Support
45
Commissioning
46
Oil Supply
46
Fig. 26: Oil Orifice
47
Inspection Procedures
48
Commissioning after Taking out of Operation
50
Monitoring Operation
51
Oil Pressure, Oil Temperature
51
Table 8: Lubricating Oil Pressure at Oil Inlet before Turbocharger
51
Table 9: Lubricating Oil Temperature at the Inlet
52
Table 10: Lubricating Oil Temperature at the Outlet
52
Exhaust Gas Temperature before Turbine
53
Turbocharger Speed
54
Fig. 27: Layout and Overview of Speed Measurement System
54
Fig. 28: Replacing the Speed Sensor
56
Table 11: Tightening Torque (86505)
56
Operation and Service
57
Noise Emission
57
Fig. 29: Noise Insulation, Bellows
58
Service Work
59
Fig. 30: Replacing the Protective Grid
61
Expected Replacement Intervals
63
Table 12: Expected Replacement Intervals
63
Stopping the Engine
65
Periodic Maintenance Work
66
Foreword to Maintenance
66
Table 13: Maintenance Table
66
Cleaning the Compressor During Operation
67
Table 14: Parameters for Wet Cleaning of Compressor
69
Fig. 31: Carrying out Wet Cleaning of Compressor
69
Cleaning the Turbine During Operation
70
Table 15: Turbine Wet Cleaning, Recommended Operating State
72
Fig. 32: Carrying out Wet Cleaning of Turbine
73
Table 16: Wet Cleaning of Turbine, Parameters
73
Cleaning Components Mechanically
74
Fig. 33: Cleaning the Filter Silencer
75
Fig. 34: Compressor-End, Non-Rotating Parts
77
Fig. 35: Turbine End, Non-Rotating Parts
79
Fig. 36: Soaking the Turbine End
81
Table 17: Value Table for Soaking
81
Table 20: Malfunctions When Starting - Rubbing of Rotating Parts
84
Table 19: Malfunctions When Starting - Vibrations
84
Table 18: Malfunctions When Starting - Delayed Start-Up
84
Malfunctions When Starting
84
Eliminating Malfunctions
84
Malfunctions During Operation
85
Table 21: Malfunctions During Operation - Lubricating Oil Pressure too Low
85
Table 22: Malfunctions During Operation - Speed Reduces
85
Table 23: Malfunctions During Operation - Speed Increases
85
Table 24: Malfunctions During Operation - Exhaust Gas Temperature too High
86
Table 25: Malfunctions During Operation - Charge Air Pressure too Low
86
Table 26: Malfunctions During Operation - Charge Air Pressure too High
87
Table 27: Malfunctions During Operation - Engine Performance Losses
87
Turbocharger Is Surging
88
Table 28: Malfunction - Turbocharger Pumping
88
Table 29: Malfunction - Sporadic Surge Blows
88
Table 31: Malfunctions When Stopping - Runout Time too Short
89
Malfunctions When Stopping
89
Table 30: Malfunctions When Stopping - Runout Noises
89
Speed Measurement System
90
Table 32: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
90
Table 33: Malfunction of the Speed Measurement System - Measured Speed too High
90
Table 34: Malfunction of the Speed Measurement System - Measured Speed too Low
90
Dismantling and Fitting
91
Introduction
91
Material Required
92
Fig. 37: Swivel Lifting Eyes
92
Table 35: Swivel Lifting Eyes
92
Fig. 38: Starpoint Ring Nut VRM
93
ABB A135-M66 Operation Manual (152 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 19.21 MB
Table of Contents
Operation Manual / A130-M - A145-M
3
Table of Contents
3
Fig. 1: Serial Number (01) on the Rating Plate
6
Operation Manual / A130-M
6
Purpose of the Manual
6
Introduction
6
Contact Information
7
Essential Information
7
Layout and Function of the Turbocharger
8
Fig. 2: Layout and Function of the Turbocharger
8
Fig. 3: Compressor Wheel Cooling
9
Symbols, Definitions
10
Table 1: Definition of Pictograms
11
Storage of New Turbochargers and Spare Parts
12
Fig. 4: Volatile Corrosion Inhibitor (VCI)
12
Fig. 5: Package with Hygrometer
13
Registered Trademarks
14
CE Conformity
15
Safety
15
Introduction
15
Definition of Mandatory Signs
16
Definition of Safety Instructions
16
Table 2: Personal Protective Equipment to be Worn at All Times
16
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
16
Intended Use
17
Deflagration on Gas Engines
18
Warning Plates on the Turbocharger
19
Fig. 6: Warning Plate Locations
19
Turbocharger Rating Plate
20
Fig. 7: Rating Plate
20
Fig. 8: Locations of the Rating Plates
21
Periodic Check of the Pressure Vessels
22
Lifting of Loads
23
Fig. 9: Attachment of Loads on the Crane Hook
23
Fig. 10: Attachment Angle
23
Prerequisites for Operation and Maintenance
24
Hazards During Operation and Maintenance
25
Safe Operation
27
Fig. 11
27
Safe Maintenance
28
Removing and Installing
32
Turbocharger Weight and Transportation
32
Fig. 12: Suspension of Complete Turbocharger Unit
32
Table 4: Weight of Complete Turbocharger Unit
32
Fig. 13: Turbine Cleaning Nozzle
33
Removing the Turbocharger
33
Fig. 14: Removing the Turbocharger
34
Fig. 15: Loosening the Clamping Nut
36
Fig. 16: Turbocharger Centre of Gravity
37
Installing the Turbocharger
38
Fig. 17: Inserting Gaskets into the Bracket
38
Fig. 18: Inserting the Threaded Rods
39
Fig. 19: Requirements for Threaded Rods
39
Table 5: Requirements for Threaded Rods
39
Fig. 20: Placing the Turbocharger on the Bracket
40
Table 6: Tightening Torque for Standard Nuts
41
Fig. 21: Preparing the Clamping Nut for the Tightening Procedure
42
Fig. 22: Tightening Pressure Screws
43
Table 7: Torque-Controlled Tightening of the Pressure Screws
43
Fig. 23: Connecting the Speed Sensor
44
Fig. 24: Connecting the Compressor Cooling Air Intake
44
Fig. 25: Attaching the Support
45
Commissioning
46
Oil Supply
46
Fig. 26: Oil Orifice
47
Inspection Procedures
48
Commissioning after Taking out of Operation
50
Monitoring Operation
51
Oil Pressure, Oil Temperature
51
Table 8: Lubricating Oil Pressure at Oil Inlet before Turbocharger
51
Table 9: Lubricating Oil Temperature at the Inlet
52
Table 10: Lubricating Oil Temperature at the Outlet
52
Exhaust Gas Temperature before Turbine
53
Turbocharger Speed
54
Fig. 27: Layout and Overview of Speed Measurement System
54
Fig. 28: Replacing the Speed Sensor
56
Table 11: Tightening Torque (86505)
56
Operation and Service
57
Noise Emission
57
Fig. 29: Noise Insulation, Bellows
58
Service Work
59
Fig. 30: Replacing the Protective Grid
61
Expected Replacement Intervals
63
Table 12: Expected Replacement Intervals
63
Stopping the Engine
65
Periodic Maintenance Work
66
Foreword to Maintenance
66
Table 13: Maintenance Table
66
Cleaning the Compressor During Operation
67
Table 14: Parameters for Wet Cleaning of Compressor
69
Fig. 31: Carrying out Wet Cleaning of Compressor
69
Cleaning the Turbine During Operation
70
Table 15: Turbine Wet Cleaning, Recommended Operating State
72
Fig. 32: Carrying out Wet Cleaning of Turbine
73
Table 16: Wet Cleaning of Turbine, Parameters
73
Cleaning Components Mechanically
74
Fig. 33: Cleaning the Filter Silencer
75
Fig. 34: Compressor-End, Non-Rotating Parts
77
Fig. 35: Turbine End, Non-Rotating Parts
78
Fig. 36: Soaking the Turbine End
81
Table 17: Value Table for Soaking
81
Table 20: Malfunctions When Starting - Rubbing of Rotating Parts
84
Table 19: Malfunctions When Starting - Vibrations
84
Table 18: Malfunctions When Starting - Delayed Start-Up
84
Malfunctions When Starting
84
Eliminating Malfunctions
84
Malfunctions During Operation
85
Table 21: Malfunctions During Operation - Lubricating Oil Pressure too Low
85
Table 22: Malfunctions During Operation - Speed Reduces
85
Table 23: Malfunctions During Operation - Speed Increases
85
Table 24: Malfunctions During Operation - Exhaust Gas Temperature too High
86
Table 25: Malfunctions During Operation - Charge Air Pressure too Low
86
Table 26: Malfunctions During Operation - Charge Air Pressure too High
87
Table 27: Malfunctions During Operation - Engine Performance Losses
87
Turbocharger Is Surging
88
Table 28: Malfunction - Turbocharger Pumping
88
Table 29: Malfunction - Sporadic Surge Blows
88
Table 31: Malfunctions When Stopping - Runout Time too Short
89
Malfunctions When Stopping
89
Table 30: Malfunctions When Stopping - Runout Noises
89
Speed Measurement System
90
Table 32: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
90
Table 33: Malfunction of the Speed Measurement System - Measured Speed too High
90
Table 34: Malfunction of the Speed Measurement System - Measured Speed too Low
90
Dismantling and Fitting
91
Introduction
91
Material Required
92
Fig. 37: Swivel Lifting Eyes
92
Table 35: Swivel Lifting Eyes
92
Fig. 38: Starpoint Ring Nut VRM
93
ABB A135-M66 Operation Manual (152 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 19.21 MB
Table of Contents
Operation Manual / A130-M - A145-M
3
Table of Contents
3
Fig. 1: Serial Number (01) on the Rating Plate
6
Operation Manual / A130-M
6
Purpose of the Manual
6
Introduction
6
Contact Information
7
Essential Information
7
Layout and Function of the Turbocharger
8
Fig. 2: Layout and Function of the Turbocharger
8
Fig. 3: Compressor Wheel Cooling
9
Symbols, Definitions
10
Table 1: Definition of Pictograms
11
Storage of New Turbochargers and Spare Parts
12
Fig. 4: Volatile Corrosion Inhibitor (VCI)
12
Fig. 5: Package with Hygrometer
13
Registered Trademarks
14
CE Conformity
15
Safety
15
Introduction
15
Definition of Mandatory Signs
16
Definition of Safety Instructions
16
Table 2: Personal Protective Equipment to be Worn at All Times
16
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
16
Intended Use
17
Deflagration on Gas Engines
18
Warning Plates on the Turbocharger
19
Fig. 6: Warning Plate Locations
19
Turbocharger Rating Plate
20
Fig. 7: Rating Plate
20
Fig. 8: Locations of the Rating Plates
21
Periodic Check of the Pressure Vessels
22
Lifting of Loads
23
Fig. 9: Attachment of Loads on the Crane Hook
23
Fig. 10: Attachment Angle
23
Prerequisites for Operation and Maintenance
24
Hazards During Operation and Maintenance
25
Safe Operation
27
Fig. 11
27
Safe Maintenance
28
Removing and Installing
32
Turbocharger Weight and Transportation
32
Fig. 12: Suspension of Complete Turbocharger Unit
32
Table 4: Weight of Complete Turbocharger Unit
32
Fig. 13: Turbine Cleaning Nozzle
33
Removing the Turbocharger
33
Fig. 14: Removing the Turbocharger
34
Fig. 15: Loosening the Clamping Nut
36
Fig. 16: Turbocharger Centre of Gravity
37
Installing the Turbocharger
38
Fig. 17: Inserting Gaskets into the Bracket
38
Fig. 18: Inserting the Threaded Rods
39
Fig. 19: Requirements for Threaded Rods
39
Table 5: Requirements for Threaded Rods
39
Fig. 20: Placing the Turbocharger on the Bracket
40
Table 6: Tightening Torque for Standard Nuts
41
Fig. 21: Preparing the Clamping Nut for the Tightening Procedure
42
Fig. 22: Tightening Pressure Screws
43
Table 7: Torque-Controlled Tightening of the Pressure Screws
43
Fig. 23: Connecting the Speed Sensor
44
Fig. 24: Connecting the Compressor Cooling Air Intake
44
Fig. 25: Attaching the Support
45
Commissioning
46
Oil Supply
46
Fig. 26: Oil Orifice
47
Inspection Procedures
48
Commissioning after Taking out of Operation
50
Monitoring Operation
51
Oil Pressure, Oil Temperature
51
Table 8: Lubricating Oil Pressure at Oil Inlet before Turbocharger
51
Table 9: Lubricating Oil Temperature at the Inlet
52
Table 10: Lubricating Oil Temperature at the Outlet
52
Exhaust Gas Temperature before Turbine
53
Turbocharger Speed
54
Fig. 27: Layout and Overview of Speed Measurement System
54
Fig. 28: Replacing the Speed Sensor
56
Table 11: Tightening Torque (86505)
56
Operation and Service
57
Noise Emission
57
Fig. 29: Noise Insulation, Bellows
58
Service Work
59
Fig. 30: Replacing the Protective Grid
61
Expected Replacement Intervals
63
Table 12: Expected Replacement Intervals
63
Stopping the Engine
65
Periodic Maintenance Work
66
Foreword to Maintenance
66
Table 13: Maintenance Table
66
Cleaning the Compressor During Operation
67
Table 14: Parameters for Wet Cleaning of Compressor
69
Fig. 31: Carrying out Wet Cleaning of Compressor
69
Cleaning the Turbine During Operation
70
Table 15: Turbine Wet Cleaning, Recommended Operating State
72
Fig. 32: Carrying out Wet Cleaning of Turbine
73
Table 16: Wet Cleaning of Turbine, Parameters
73
Cleaning Components Mechanically
74
Fig. 33: Cleaning the Filter Silencer
75
Fig. 34: Compressor-End, Non-Rotating Parts
77
Fig. 35: Turbine End, Non-Rotating Parts
78
Fig. 36: Soaking the Turbine End
81
Table 17: Value Table for Soaking
81
Table 20: Malfunctions When Starting - Rubbing of Rotating Parts
84
Table 19: Malfunctions When Starting - Vibrations
84
Table 18: Malfunctions When Starting - Delayed Start-Up
84
Malfunctions When Starting
84
Eliminating Malfunctions
84
Malfunctions During Operation
85
Table 21: Malfunctions During Operation - Lubricating Oil Pressure too Low
85
Table 22: Malfunctions During Operation - Speed Reduces
85
Table 23: Malfunctions During Operation - Speed Increases
85
Table 24: Malfunctions During Operation - Exhaust Gas Temperature too High
86
Table 25: Malfunctions During Operation - Charge Air Pressure too Low
86
Table 26: Malfunctions During Operation - Charge Air Pressure too High
87
Table 27: Malfunctions During Operation - Engine Performance Losses
87
Turbocharger Is Surging
88
Table 28: Malfunction - Turbocharger Pumping
88
Table 29: Malfunction - Sporadic Surge Blows
88
Table 31: Malfunctions When Stopping - Runout Time too Short
89
Malfunctions When Stopping
89
Table 30: Malfunctions When Stopping - Runout Noises
89
Speed Measurement System
90
Table 32: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
90
Table 33: Malfunction of the Speed Measurement System - Measured Speed too High
90
Table 34: Malfunction of the Speed Measurement System - Measured Speed too Low
90
Dismantling and Fitting
91
Introduction
91
Material Required
92
Fig. 37: Swivel Lifting Eyes
92
Table 35: Swivel Lifting Eyes
92
Fig. 38: Starpoint Ring Nut VRM
93
ABB A135-M66 Operation Manual (144 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 17.44 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
Essential Information
33
Introduction
33
Registered Trademarks
33
Related Documents
33
Table 1: Related Documents
33
Fig. 1: Layout and Function of the Turbocharger
34
Layout and Function of the Turbocharger
34
Fig. 2: Compressor Wheel Cooling
35
Fig. 3: Warning Plate Locations
36
Warning Plates on the Turbocharger
36
Fig. 4: Locations of the Rating Plates
37
Locations of the Rating Plates
37
Fig. 5: Suspension of Complete Turbocharger Unit
38
Removing and Installing
38
Table 2: Weight of Complete Turbocharger Unit
38
Turbocharger Weight and Transportation
38
Fig. 6: Turbine Cleaning Nozzle
39
Removing the Turbocharger
39
Fig. 7: Removing the Turbocharger
40
Fig. 8: Loosening the Clamping Nut
42
Fig. 9: Turbocharger Centre of Gravity
43
Fig. 10: Inserting Gaskets into the Bracket
44
Installing the Turbocharger
44
Fig. 11: Inserting the Threaded Rods
45
Fig. 12: Requirements for Threaded Rods
45
Table 3: Requirements for Threaded Rods
45
Fig. 13: Placing the Turbocharger on the Bracket
46
Table 4: Tightening Torque for Standard Nuts
47
Fig. 14: Preparing the Clamping Nut for the Tightening Procedure
48
Fig. 15: Tightening Pressure Screws
49
Table 5: Torque-Controlled Tightening of the Pressure Screws
49
Fig. 16: Connecting the Speed Sensor
50
Fig. 17: Connecting the Compressor Cooling Air Intake
50
Fig. 18: Attaching the Support
51
Commissioning
52
Oil Supply
52
Fig. 19: Oil Orifice
53
Inspection Procedures
54
Commissioning after Taking out of Operation
56
Monitoring Operation
57
Oil Pressure, Oil Temperature
57
Table 6: Lubricating Oil Pressure at Oil Inlet before Turbocharger
57
Table 7: Lubricating Oil Temperature at the Inlet
58
Table 8: Lubricating Oil Temperature at the Outlet
58
Exhaust Gas Temperature before Turbine
59
Fig. 20: Layout and Overview of Speed Measurement System
60
Turbocharger Speed
60
Fig. 21: Replacing the Speed Sensor
62
Table 9: Tightening Torque (86505)
62
Noise Emission
63
Operation and Service
63
Fig. 22: Noise Insulation, Bellows
64
Service Work
65
Fig. 23: Replacing the Protective Grid
67
Expected Replacement Intervals
69
Table 10: Expected Replacement Intervals
69
Stopping the Engine
71
Foreword to Maintenance
72
Periodic Maintenance Work
72
Table 11: Maintenance Table
72
Cleaning the Compressor During Operation
73
Fig. 24: Carrying out Wet Cleaning of Compressor
75
Table 12: Parameters for Wet Cleaning of Compressor
75
Cleaning the Turbine During Operation
76
Table 13: Turbine Wet Cleaning, Recommended Operating State
78
Fig. 25: Carrying out Wet Cleaning of Turbine
79
Table 14: Wet Cleaning of Turbine, Parameters
79
Cleaning Components Mechanically
80
Fig. 26: Cleaning the Filter Silencer
81
Fig. 27: Compressor-End, Non-Rotating Parts
83
Fig. 28: Turbine End, Non-Rotating Parts
85
Fig. 29: Soaking the Turbine End
87
Table 15: Value Table for Soaking
87
Eliminating Malfunctions
90
Malfunctions When Starting
90
Table 16: Malfunctions When Starting - Delayed Start-Up
90
Table 17: Malfunctions When Starting - Vibrations
90
Table 18: Malfunctions When Starting - Rubbing of Rotating Parts
90
Malfunctions During Operation
91
Table 19: Malfunctions During Operation - Lubricating Oil Pressure too Low
91
Table 20: Malfunctions During Operation - Speed Reduces
91
Table 21: Malfunctions During Operation - Speed Increases
91
Table 22: Malfunctions During Operation - Exhaust Gas Temperature too High
92
Table 23: Malfunctions During Operation - Charge Air Pressure too Low
92
Table 24: Malfunctions During Operation - Charge Air Pressure too High
93
Table 25: Malfunctions During Operation - Engine Performance Losses
93
Table 26: Malfunction - Turbocharger Pumping
94
Table 27: Malfunction - Sporadic Surge Blows
94
Turbocharger Is Surging
94
Malfunctions When Stopping
95
Table 28: Malfunctions When Stopping - Runout Noises
95
Table 29: Malfunctions When Stopping - Runout Time too Short
95
Speed Measurement System
96
Table 30: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
96
Table 31: Malfunction of the Speed Measurement System - Measured Speed too High
96
Table 32: Malfunction of the Speed Measurement System - Measured Speed too Low
96
Dismantling and Fitting
97
Introduction
97
Fig. 30: Swivel Lifting Eyes
98
Material Required
98
Table 33: Swivel Lifting Eyes
98
Fig. 31: Starpoint Ring Nut VRM
99
Weights of Individual Parts
99
ABB A135-M66 Operation Manual (144 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 25.54 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
24
Product Description
31
Essential Information
33
Introduction
33
Registered Trademarks
33
Related Documents
33
Table 1: Related Documents
33
Fig. 1: Layout and Function
34
Layout and Function of the Turbocharger
34
Fig. 2: Connection of the Compressor Wheel Cooling
35
Fig. 3: Warning Plates on the Turbocharger
36
Warning Plates on the Turbocharger
36
Fig. 4: Locations of the Rating Plates
37
Locations of the Rating Plates
37
Fig. 5: Turbocharger Suspension Points
38
Removal and Installation
38
Table 2: Weight of Complete Turbocharger Unit
38
Turbocharger Weight
38
Fig. 6: Turbocharger Suspension Points
39
Removing the Turbocharger
39
Fig. 7: Removing the Foot Mounting
40
Fig. 8: Loosening the Clamping Nut
41
Fig. 9: Turbocharger Suspension Points
42
Installing the Turbocharger
42
Fig. 10: Removing Auxiliary Screw
43
Fig. 11: Compressor-End Foot
44
Fig. 12: Turbine-End Foot
44
Table 3: Foot Screws, Dimension and Strength Class
44
Table 4: Foot Screws, Dimension CE
44
Table 5: Foot Screws, Dimension te
44
Table 6: Foot Screws, Number of Cup Springs
45
Fig. 13: CE Foot Contact Surface
46
Fig. 14: te Foot: Handling of Cup Spring Contact Surface / Foot Contact Surface
46
Fig. 15: Tightening the Foot Screws (1)
47
Fig. 16: Tightening Procedure
48
Table 7: Torque-Controlled Tightening of the Pressure Screws
48
Commissioning
49
Oil Supply
49
Inspection Procedures
50
Commissioning after Taking out of Operation
51
Fig. 17: Lubricating Oil Pressure Measuring Point
52
Monitoring During Operation
52
Oil Pressure, Oil Temperature
52
Table 8: Oil Pressure Range
52
Table 10: Oil Temperature at the Outlet
53
Table 9: Oil Temperature at the Inlet
53
Fig. 18: Speed Measurement
54
Turbocharger Speed
54
Noise Emission
57
Operation and Service
57
Fig. 19: Noise Insulation, Bellows
58
Service Work
59
Expected Replacement Intervals
62
Stopping the Engine
63
Table 11: Expected Replacement Intervals
63
Table 12: Recommended Replacement Intervals
63
Foreword to Maintenance
64
Periodic Maintenance
64
Cleaning the Filter Silencer
65
Fig. 20: Cleaning the Filter Silencer
65
Fig. 21: Cleaning the Filter Silencer (2)
67
Table 13: Tightening Torque (81272)
67
Table 14: Tightening Torque (81273)
67
Cleaning the Slotted Diffuser
68
Fig. 22: Cleaning the Slotted Diffuser
68
Cleaning the Compressor During Operation
69
Table 15: Compressor Cleaning Parameters
71
Fig. 23: Operation of Water Pressure Vessel
73
Table 16: Compressor Cleaning Parameters
74
Cleaning Turbine and Nozzle Ring
75
Fig. 24: Turbine and Nozzle Ring Cleaning Cycle
77
Fig. 25: Cleaning Cycle of Turbine and Nozzle Ring with Load Ramp
78
Fig. 26: Procedure Wet Cleaning of Turbine and Nozzle Ring
79
Table 17: Cleaning Parameters Wet Cleaning of Turbine and Nozzle Ring
80
Malfunctions When Starting
81
Table 18: Malfunctions When Starting - Delayed Start-Up
81
Table 19: Malfunctions When Starting - Vibrations
81
Table 20: Malfunctions When Starting - Rubbing of Rotating Parts
81
Troubleshooting
81
Malfunctions During Operation
82
Table 21: Malfunctions During Operation - Lubricating Oil Pressure too Low
82
Table 22: Malfunctions During Operation - Drop in Speed
82
Table 23: Malfunctions During Operation - Speed Increases
82
Table 24: Malfunctions During Operation - Exhaust Gas Temperature too High
83
Table 25: Malfunctions During Operation - Charge Air Pressure too Low
83
Surging of the Turbocharger
84
Table 26: Malfunctions During Operation - Charge Air Pressure too High
84
Table 27: Surging of the Turbocharger
84
Malfunctions When Stopping
85
Table 28: Malfunctions When Stopping - Runout Noises
85
Table 29: Malfunctions When Stopping - Shortened Runout Time
85
Speed Measurement System
86
Table 30: Malfunction, no Speed Measurement Signal or Poor Signal Amplitude
86
Table 31: Malfunction, Measured Speed too High
86
Table 32: Malfunction, Measured Speed too Low
86
Disassembly and Assembly
87
Introduction
87
Fig. 27: Weight of Assemblies
89
Table 33: Assembly Weights
89
Weight of Assemblies
89
Fig. 28: Removing the Filter Silencer
90
Removing the Air Inlets
90
Fig. 29: Removing the Air Suction Branch
91
Axial Clearance a Prior to Disassembly
92
Fig. 30: Axial Clearance
92
Table 34: Axial Clearance a
92
Fig. 31: Removing Wall Insert
93
Removing the Compressor Casing
93
Fig. 32: Transporting and Turning Wall Insert
94
Fig. 33: Removing the Diffuser
94
Fig. 34: Removing the Compressor Casing
95
Fig. 35: Safety-Relevant Screws
96
Removing the Cartridge Group
96
Fig. 36: Removing Cartridge Group 1
97
Fig. 37: Removing Cartridge Group 2
98
Fig. 38: Removing Turbine Diffuser 1
99
Fig. 39: Removing Turbine Diffuser 2
99
Removing the Nozzle Ring
99
Fig. 40: Removing Cover Ring 1
100
Fig. 41: Removing Cover Ring 2
101
Fig. 42: Removing Nozzle Ring 1
101
Fig. 43: Removing Nozzle Ring 2
102
Fig. 44: Installing Nozzle Ring 1
103
Installing the Nozzle Ring
103
Fig. 45: Installing Nozzle Ring 2
104
Table 35: Tightening Torque (56014)
104
Fig. 46: Installing Cover Ring
105
Table 36: Tightening Torque (57005)
105
Fig. 47: Installing Turbine Diffuser 1
106
Fig. 48: Installing Turbine Diffuser 2
107
Table 37: Tightening Torque (61069)
107
Fig. 49: Installing the Cartridge Group 1
108
Installing the Cartridge Group
108
Fig. 50: Installing the Cartridge Group 2
109
Table 38: Tightening Torque (61059 / 42128)
109
Fig. 51: Installing the Cartridge Group 3
110
Table 39: Tightening Torque (86505)
110
Fig. 52: Preparing the Threaded Stud (25008)
111
Fitting the Spinner Nose Cone
111
Table 40: Inner Thread Size (25008)
111
Fig. 53: Fitting the Spinner Nose Cone (25012)
112
Table 41: Tightening Torque (25013)
112
Fig. 54: Installing the Compressor Casing
113
Installing the Compressor Casing
113
Table 42: Tightening Torque (61037)
113
Table 43: Tightening Torque, Nuts that Are Difficult
113
Table 44: Tightening Torque (61090)
113
Fig. 55: Installing Diffuser
114
Table 45: Tightening Torque (77015)
114
Fig. 56: Turning and Moving in Wall Insert
115
Fig. 57: Fitting Wall Insert
116
Table 46: Tightening Torque (72011)
116
Axial Clearance a after Assembly
117
Fig. 58: Axial Clearance
117
Table 47: Axial Clearance a
117
Fig. 59: Installing the Air Suction Branch
118
Installing the Air Inlets
118
Table 48: Tightening Torque (27027)
118
Fig. 60: Installing the Filter Silencer
119
Table 49: Tightening Torque (27027)
119
Removing and Installing Turbine-End Nozzle Ring
120
Fig. 61: Removing the Nozzle Ring at the Turbine End
121
Fig. 62: Installing the Nozzle Ring at the Turbine End
122
Table 50: Tightening Torque (56014)
122
Table 51: Tightening Torque (61009)
123
Fig. 63: Tightening Torques 1
124
Fig. 64: Tightening Torques 2
124
Table of Tightening Torques
124
Table 52: Tightening Torques
125
Fig. 65: Flange Tightening Sequence
126
Table 53: Tightening Torques 61009
126
Possible Emergency Repairs
127
Taking a Turbocharger out of Operation
127
Locking the Rotor
128
Fig. 66: Fitting the Locking Device
129
Table 54: Locking Device Tightening Torque
129
Fig. 67: Cover Plate (01) / Spacer Sleeves (02) Dimensions
131
Fitting the Cover Plate
131
Table 55: Cover Plate Dimensions 1
131
Table 56: Cover Plate Dimensions 2
131
Table 57: Cover Plate Dimensions 3
131
Fig. 68: Fitting the Cover Plate
132
Blanking off the Inlets and Outlets
133
Engines with Bypass Around the Turbocharger
133
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
Disposing of Turbocharger Components
136
Ordering Spare Parts
137
Spare Parts
137
Fig. 69: Turbocharger with Part Numbers
138
Table 58: Customer Spare Part Set (97070)
138
View of Turbocharger with Part Numbers
138
Tools
140
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