Abb A155-M Series Manuals

Table of Contents

3

Operation Manual / A150-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

Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task

16

Definition of Safety Instructions

16

Table 2: Personal Protective Equipment to be Worn at All Times

16

Definition of Mandatory Signs

16

Intended Use

17

Warning Plates on the Turbocharger

18

Fig. 6: Warning Plate Locations

18

Turbocharger Rating Plate

19

Fig. 7: Rating Plate

19

Fig. 8: Locations of the Rating Plates

20

Periodic Check of the Pressure Vessels

21

Fig. 10: Attachment Angle

22

Fig. 9: Attachment of Loads on the Crane Hook

22

Lifting of Loads

22

Prerequisites for Operation and Maintenance

23

Hazards During Operation and Maintenance

24

Safe Operation

26

Safe Maintenance

27

Removing and Installing

31

Turbocharger Weight and Transportation

31

Fig. 11: Suspension of Complete Turbocharger Unit

31

Table 4: Weight of Complete Turbocharger Unit

31

Removing the Turbocharger

32

Fig. 12: Turbine Cleaning Nozzle

32

Fig. 13: Removing the Turbocharger

33

Fig. 14: Loosening the Clamping Nut

34

Fig. 15: Turbocharger Centre of Gravity

35

Installing the Turbocharger

36

Fig. 16: Inserting the Gasket

36

Fig. 17: Fitting the Turbocharger 1

37

Fig. 18: Fitting the Turbocharger 2

38

Table 5: Fitting the Turbocharger, Value X, L

38

Fig. 19: Preparing the Clamping Nut for the Tightening Procedure

39

Table 6: Torque-Controlled Tightening of the Pressure Screws

40

Fig. 20: Tightening Pressure Screws

40

Fig. 21: Connecting the Speed Sensor

41

Fig. 22: Connecting the Compressor Cooling Air Intake

41

Fig. 23: Attaching the Support

41

Commissioning

42

Oil Supply

42

Fig. 24: Oil Orifice

42

Inspection Procedures

44

Commissioning after Taking out of Operation

46

Table 7: Lubricating Oil Pressure at Oil Inlet before Turbocharger

47

Monitoring Operation

47

Oil Pressure, Oil Temperature

47

Table 8: Lubricating Oil Temperature at the Inlet

48

Table 9: Maximum Lubricating Oil Temperature at the Outlet

48

Exhaust Gas Temperature before Turbine

49

Turbocharger Speed

50

Fig. 25: Layout and Overview of Speed Measurement System

50

Fig. 26: Replacing the Speed Sensor

52

Table 10: Tightening Torque (86505)

52

Noise Emission

53

Operation and Service

53

Fig. 27: Noise Insulation, Bellows

54

Service Work

55

Expected Replacement Intervals

58

Table 11: Expected Replacement Intervals

58

Stopping the Engine

60

Periodic Maintenance Work

61

Foreword to Maintenance

61

Table 12: Maintenance Table

61

Cleaning the Compressor During Operation

62

Fig. 28: Carrying out Wet Cleaning of Compressor

64

Table 13: Parameters for Wet Cleaning of Compressor

64

Cleaning the Turbine During Operation

65

Fig. 29: Turbine Cleaning Devices

67

Table 14: Turbine Wet Cleaning, Recommended Operating State

67

Fig. 30: Carrying out Wet Cleaning of Turbine

68

Table 15: Wet Cleaning of Turbines, Parameters for 1-Nozzle Cleaning

68

Cleaning Components Mechanically

69

Table 16: Wet Cleaning of Turbines, Parameters for 6-Nozzle Cleaning

69

Fig. 31: Cleaning the Filter Silencer

70

Fig. 32: Cleaning the Filter Silencer

72

Fig. 33: Cleaning the Filter Silencer (2)

74

Table 17: Tightening Torque (81272)

74

Table 18: Tightening Torque (81273)

74

Fig. 34: Compressor-End, Non-Rotating Parts

75

Fig. 35: Turbine End, Non-Rotating Parts

76

Fig. 36: Soaking the Turbine End

79

Table 19: Value Table for Soaking

79

Changing the Absorption Element

82

Fig. 37: Disassembling the Absorption Element

82

Table 20: Tightening Torque (81152 / 81154)

83

Fig. 38: Installing the Absorption Element

83

Eliminating Malfunctions

84

Malfunctions When Starting

84

Table 21: Malfunctions When Starting - Delayed Start-Up

84

Table 22: Malfunctions When Starting - Vibrations

84

Table 23: Malfunctions When Starting - Rubbing of Rotating Parts

84

Malfunctions During Operation

85

Table 24: Malfunctions During Operation - Lubricating Oil Pressure too Low

85

Table 25: Malfunctions During Operation - Speed Reduces

85

Table 26: Malfunctions During Operation - Speed Increases

85

Table 27: Malfunctions During Operation - Exhaust Gas Temperature too High

86

Table 28: Malfunctions During Operation - Charge Air Pressure too Low

86

Table 29: Malfunctions During Operation - Charge Air Pressure too High

87

Table 30: Malfunctions During Operation - Engine Performance Losses

87

Turbocharger Is Surging

88

Table 31: Malfunction - Turbocharger Surging

88

Table 32: Malfunction - Sporadic Surge Blows

88

Malfunctions When Stopping

89

Table 33: Malfunctions When Stopping - Runout Noises

89

Table 34: Malfunctions When Stopping - Runout Time too Short

89

Table 37: Malfunction of the Speed Measurement System - Measured Speed too Low

90

Table 35: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude

90

Table 36: Malfunction of the Speed Measurement System - Measured Speed too High

90

Speed Measurement System

90

Dismantling and Fitting, General

91

Introduction

91

Material Required

92

Fig. 39: Swivel Lifting Eye (Example)

92

Table 38: Swivel Lifting Eyes

92

Table 40: Dismantling Screw

93

Table 39: Press-Off Screws

93

Fig. 41: Dismantling Screw

93

Fig. 40: Press-Off Screws

93

Disassembly and Assembly Concepts

95

Fig. 42: Removing the Cartridge Group with Compressor and Turbine Casing

95

Fig. 43: Cartridge Concept

96

Fig. 44: Optional Spanner Holder

97

Weights of Individual Parts

98

Fig. 45: Weights of Assemblies

98

Table 41: Weights of Assemblies

98

Table 42: Tightening Torques

99

Fig. 46: Overview of Tightening Torques

99

Table of Tightening Torques

99

Fig. 47: Tightening Torques for Insulation

100

Table 43: Tightening Torques for Insulation

100

Dismantling and Fitting with Removed Air Inlet and Gas Outlet

101

Removing Air Inlets

101

Fig. 48: Removing the Air Inlets

101

Fig. 49: Removing the Uncoupled Filter Silencer

102

Removing the Gas Outlet Casing

103

Fig. 50: Remove Gas Outlet Casing Without Support

103

Fig. 51: Removing Gas Outlet Casing with Support 1

104

Fig. 52: Removing Gas Outlet Casing with Support 1

105

Removing the Gas Outlet Flange

106

Fig. 53: Dismantling the Gas Outlet Flange

107

Table 44: 3 Press-Off Screws

107

Fig. 54: Removing the Gas Outlet Flange

108

Table 45: 6 Press-Off Screws

108

Removing the Cartridge Group with Compressor and Turbine Casing

109

Fig. 55: Turbine Cleaning Nozzle

109

Fig. 56: Remove Insulation

109

Fig. 57: Removing the Cartridge Group with Compressor and Turbine Casing

110

Fig. 58: Setting down the Cartridge Group with the Compressor and Turbine Casing

110

Removing the Compressor Casing

111

Fig. 59: Removing the Compressor Casing

111

Fig. 60: Dismantling the Diffuser and the Wall Insert

112

Removing the Cartridge Group

113

Fig. 61: Removing Cartridge Group 1

113

Table 46: Tightening Torque (90012-01)

113

Fig. 62: Removing Cartridge Group 2

114

Fig. 63: Removing Cartridge Group 3

115

Installing the Cartridge Group on the Service Support

116

Fig. 64: Installing the Cartridge Group on the Service Support

116

Removing the Nozzle Ring

117

Fig. 65: Removing the Nozzle Ring

117

Measuring Clearance a and B

118

Fig. 66: Measuring Clearance a and B

118

Table 47: Permissible Clearances a and B

118

Nozzle Ring Compression PD

119

Fig. 67: Nozzle Ring Compression PD

119

Table 48: Nozzle Ring Compression PD

119

Installing Nozzle Ring

120

Fig. 68: Installing the Nozzle Ring

120

Installing the Cartridge Group

121

Fig. 69: Lifting the Cartridge Group and Rotating It

121

Fig. 70: Turning the Cartridge Group

122

Table 49: Tightening Torque (90012-01)

122

Fig. 71: Installing the Cartridge Group

123

Table 50: Tightening Torque (51007)

123

Installing the Compressor Casing

124

Fig. 72: Fitting the Wall Insert and the Diffuser

124

Table 51: Tightening Torque (79041)

124

Table 52: Tightening Torque (72011)

125

Fig. 73: Installing the Compressor Casing

125

Turning the Cartridge Group with Compressor and Turbine Casing

126

Fig. 74: Turning the Cartridge Group with Compressor and Turbine Casing

126

Installing the Gas Outlet Flange

127

Fig. 75: Installing the Gas Outlet Flange

127

Radial Clearances N and R

128

Fig. 76: Measuring Clearances N and R

128

Table 53: Permissible Clearances N and R

128

Fitting the Insulation

129

Fig. 77: Fitting the Insulation

129

Fig. 79: Installing the Cartridge Group with Compressor and Turbine Casing

130

Fig. 78: Installing the Cartridge Group with Compressor and Turbine Casing

130

Installing the Cartridge Group with Compressor and Turbine Casing

130

Installing the Gas Outlet Casing

131

Fig. 80: Fitting Gas Outlet Casing Without Support

131

Table 54: Tightening Torque (51009)

131

Fig. 81: Installing Gas Outlet Casing with Support 1

132

Table 55: Tightening Torque (51009)

132

Fig. 82: Installing Gas Outlet Casing with Support 2

133

Table 56: Tightening Torque (72051)

134

Fig. 83: Installing the Air Inlets

134

Installing Air Inlets

134

Fig. 84: Installing the Uncoupled Filter Silencer

135

Table 57: Tightening Torque (72054)

135

Dismantling and Fitting, Cartridge Concept

136

Removing Air Inlets

136

Fig. 85: Removing the Air Inlets

136

Fig. 86: Removing the Uncoupled Filter Silencer

137

Removing the Compressor Casing

138

Fig. 87: Removing the Compressor Casing

138

Fig. 88: Pressing off Compressor Casing

139

Fig. 89: Remove the Diffuser

139

Fig. 90: Dismantling the Diffuser and the Wall Insert

140

Fig. 91: Removing Insulation Sheets

141

Fig. 92: Removing Cartridge Group 1

141

Table 58: Threaded Rod, Value X

141

Fig. 93: Removing Cartridge Group 2

142

Fig. 94: Removing Cartridge Group 2

143

Fig. 95: S_05180

144

Fig. 96: Measuring Clearance a and B

145

Table 59: Permissible Clearances a and B

145

Fig. 97: Nozzle Ring Compression PD

146

Table 60: Nozzle Ring Compression PD

146

Fig. 98: Installing the Nozzle Ring

147

Fig. 99: Installing the Cartridge Group 1

148

Fig. 100: Installing the Cartridge Group 2

149

Table 61: Threaded Rod, Value X and L

149

Table 62: Tightening Torque (51007)

149

Fig. 101: Fitting the Wall Insert and the Diffuser

150

Table 63: Tightening Torque (79041)

150

Fig. 102: Installing the Compressor Casing

151

Table 64: Tightening Torque (72011)

151

Fig. 103: Measuring Clearances N and R

152

Table 65: Permissible Clearances N and R

152

Fig. 104: Fitting the Insulation

153

Fig. 105: Installing the Air Inlets

154

Table 66: Tightening Torque (72051)

154

Fig. 106: Installing the Uncoupled Filter Silencer

155

Table 67: Tightening Torque (72054)

155

Dismantling and Fitting, Special Tools for Fastening Strips

156

Fig. 107: Customer Tool

156

Fig. 108: Customer Tool

156

Table 68: Customer Tool

156

Table 69: Customer Tool

156

Fig. 110: Removing the Fastening Strips

157

Fig. 109: Positioning the Collection Tub

157

Application, Special Tools

157

Fig. 111: Fitting the Upper Fastening Strips

158

Fig. 112: Fitting the Bottom Fastening Strip

158

Table 70: Tightening Torque (51007)

158

Fig. 113: Fitting the Bottom Fastening Strip

159

Table 71: Tightening Torque (51007) with Spanner Holder

159

Fig. 114: Fitting the Cartridge Group

160

Table 72: Tightening Torque (51007)

160

Fig. 115: Positioning the Fastening Strip

161

Fig. 116: Clamping Piece

162

Fig. 117: Attach Nut

163

Table 73: Tightening Torque (51007) with Spanner Holder

163

Removing and Installing 6-Nozzle Turbine Cleaning Component (Optional)

164

Disassembly

164

Fig. 118: Initial Situation

164

Fig. 119: Disassembly of the Elbows

164

Fig. 120: Disassembly of the Elbows

165

Fig. 121: Pipe Disassembly

165

Table 74: Dismantling Screw

166

Fig. 123: Disassembly of the Cleaning Nozzle

166

Fig. 122: Disassembly of the Connecting Pieces

166

Assembly

167

Fig. 124: Assembly of the Cleaning Nozzle

167

Fig. 125: Assembly of the Connecting Pieces

167

Table 75: Dismantling Screw

167

Fig. 126: Pipe Assembly

168

Fig. 127: Elbow 1 Assembly

168

Fig. 128: Elbow 2 Assembly

169

Table 76: Tightening Torque (51314 / 51316)

169

Fig. 129: Fit the Cleaning Nozzles

170

Fitting the Cleaning Nozzles with Multi-Inlet Turbine Casings

170

Taking out of Operation at Short Notice

171

Possible Emergency Repairs

171

Installing the Replacement Turbocharger

172

Installing the Replacement Cartridge Group

172

Fitting the Cover Plate

173

Fig. 130: Fitting the Cover Plate

173

Table 77: Cover Plate Dimensions [MM]

174

Fig. 131: Cover Plate Drawing

174

Cover Plate Drawing

174

Table 78: Cover Plate Dimensions [MM]

175

Fig. 132: Dimensions for Cover Plate

175

Mothballing the Turbocharger

176

Taking the Engine out of Operation for up to 12 Months

176

Taking the Engine out of Operation for more than 12 Months

177

Material and Disposal

178

REACH and Rohs Compliance Declaration for Products

178

Disposing of Turbocharger Components

179

Required Customer Spare Part Set (97070)

180

Table 79: Customer Spare Part Set 97070

180

Ordering Spare Parts

180

Spare Parts

180

Spare Part - Illustrations

181

Table 80: Spare Parts - Cartridge, Oil Cooled

181

Table 81: Spare Parts - Bearing, Casing Oil Cooled

182

Table 82: Spare Parts - Rotor and Bearing Parts

183

Table 83: Spare Parts - Turbine Casing, 1 Inlet

184

Table 84: Spare Parts - Turbine Casing, 2 Inlets

185

Table 85: Spare Parts - Turbine Casing, 3 Inlets

186

Table 86: Spare Parts - Cleaning Device

187

Table 87: Spare Parts - Gas Outlet Casing, Radial

188

Table 88: Spare Parts - Compressor Casing

189

Table 89: Spare Parts - Filter Silencer

191

Table 90: Spare Parts - Air Suction Branch Axial

191

Table 91: Spare Parts - Air Suction Branch Radial

192

Table 92: Spare Parts - Speed Measurement System

193

Tools

194

Fig. 133: Special Tool

194

Table 93: Customer Tool Set 90000

194

Table 94: Special Tool (90160)

194

Fig. 134: Special Tool

195

Table 95: Special Tool (90160)

195

ABB A155-M Series Manuals

Table of Contents

Operation Manual / A150-M - A155-M

Table of Contents

Operation Manual / A150-M - A155-M

Table of Contents

Operation Manual / A150-M - A155-M

Table of Contents

Operation Manual / A150-M - A155-M

Table of Contents

Operation Manual / A150-M - A155-M

Table of Contents

Operation Manual / A150-M - A155-M

Table of Contents

Introduction

Safety

Product Description

Table of Contents

Operation Manual / A150-M - A155-M

Table of Contents

Operation Manual / A150-M - A155-M

Table of Contents

Operation Manual / A150-M - A155-M

Table of Contents

Operation Manual / A150-M - A155-M

Table of Contents

Operation Manual / A150-M - A155-M

Table of Contents

Operation Manual / A150-M - A155-M

Table of Contents

Operation Manual / A150-M - A155-M

Table of Contents

Operation Manual / A150-M - A155-M

Table of Contents

Operation Manual / A150-M - A155-M

Table of Contents

Operation Manual / A150-M - A155-M

Table of Contents

Operation Manual / A150-M - A155-M

Table of Contents

Operation Manual / A150-M - A155-M

Table of Contents

Operation Manual / A150-M - A155-M

Table of Contents

Operation Manual / A150-M - A155-M

Table of Contents

Operation Manual / A150-M - A155-M

Table of Contents

Operation Manual / A150-M - A155-M

Table of Contents

Operation Manual / A150-M - A155-M

Table of Contents

Operation Manual / A150-M - A155-M

Table of Contents

Operation Manual / A150-M - A155-M

Table of Contents

Operation Manual / A150-M - A155-M

Table of Contents

Operation Manual / A150-M - A155-M

Table of Contents

Operation Manual / A150-M - A155-M

Table of Contents

Introduction

Safety

Product Description

Table of Contents

1 Introduction

2 Safety

3 Weight and Transportation of the Turbocharger

4 Installing the Turbocharger

5 Storage of New Turbochargers and Spare Parts

6 Further Information

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