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A135-M55
ABB A135-M55 User Manual
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Operating limits and replacement intervals
The recommended replacement intervals and the corresponding operating limits in
chapter 3
are jointly defined
with the enginebuilder. This information is specific to the product.
Non-observance of the recommended replacement intervals and the operating limits increases the risk of unpre-
dictable component failures.
1
3
Table of Contents
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
12
Introduction
12
CE Conformity
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
Introduction
33
Essential Information
33
Registered Trademarks
33
Related Documents
33
Table 1: Related Documents
33
Layout and Function of the Turbocharger
34
Fig. 1: Layout and Function of the Turbocharger
34
Fig. 2: Compressor Wheel Cooling
35
Warning Plates on the Turbocharger
36
Fig. 3: Warning Plate Locations
36
Locations of the Rating Plates
37
Fig. 4: Locations of the Rating Plates
37
Removing and Installing
38
Turbocharger Weight and Transportation
38
Fig. 5: Suspension of Complete Turbocharger Unit
38
Table 2: Weight of Complete Turbocharger Unit
38
Removing the Turbocharger
39
Fig. 6: Turbine Cleaning Nozzle
39
Fig. 7: Removing the Turbocharger
40
Fig. 8: Loosening the Clamping Nut
42
Fig. 9: Turbocharger Centre of Gravity
43
Installing the Turbocharger
44
Fig. 10: Inserting Gaskets into the Bracket
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
Turbocharger Speed
60
Fig. 20: Layout and Overview of Speed Measurement System
60
Fig. 21: Replacing the Speed Sensor
62
Table 9: Tightening Torque (86505)
62
Operation and Service
63
Noise Emission
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
Periodic Maintenance Work
72
Foreword to Maintenance
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
Turbocharger Is Surging
94
Table 26: Malfunction - Turbocharger Pumping
94
Table 27: Malfunction - Sporadic Surge Blows
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
Material Required
98
Fig. 30: Swivel Lifting Eyes
98
Table 33: Swivel Lifting Eyes
98
Weights of Individual Parts
99
Fig. 31: Starpoint Ring Nut VRM
99
Fig. 32: Weights of Assemblies
100
Table 34: Weights of Assemblies
100
Removing the Air Inlets
101
Fig. 33: Removing the Air Inlets
101
Removing the Gas Outlet Casing
102
Fig. 34: Removing the Insulation
102
Removing the Gas Outlet Flange
103
Fig. 35: Removing the Gas Outlet Casing
103
A130 A135 A140 A145
104
Fig. 36: Dismantling the Gas Outlet Flange
104
Table 35: 3 Press-Off Screws
104
Fig. 37: Removing the Gas Outlet Flange
105
Table 36: 6 Press-Off Screws
105
Removing the Compressor Casing
106
Compressor Casing
106
Fig. 38: Removing the Compressor Casing
106
Wall Insert
107
Fig. 39: Dismantling the Wall Insert
107
Pressing off the Casing
108
Fig. 40: Press off the Casing
108
Removing the Cartridge Group
109
Cartridge Group
109
Fig. 41: Removing Insulation Sheets
109
Fig. 42: Oil Orifice
109
Fig. 43: Removing Cartridge Group 1
110
Fig. 44: Removing Cartridge Group 2
110
Removing the Nozzle Ring
111
Nozzle Ring
111
Burst Ring
111
Fig. 45: Removing the Nozzle Ring
111
Installing the Cartridge Group on the Service Support
112
Fig. 46: Installing the Cartridge Group on the Service Support
112
Measuring Clearance a and B
113
Fig. 47: Measuring Clearance a and B
113
Table 37: Permissible Clearances a and B
113
Nozzle Ring Compression PD
114
Fig. 48: Nozzle Ring Compression PD
114
Table 38: Nozzle Ring Compression PD
114
Installing the Nozzle Ring
115
Fig. 49: Installing the Nozzle Ring
115
Installing the Cartridge Group
116
Fig. 50: Lifting the Cartridge Group and Rotating It
116
Fig. 51: Installing the Cartridge Group
116
Table 39: Tightening Torque (51007)
117
Fig. 52: Turbine Casing Insulation / Burst Protection
118
Installing the Compressor Casing
119
Table 40: Tightening Torque (79041)
119
Fig. 53: Installing the Compressor Casing
120
Table 41: Tightening Torque (72011)
120
Measuring Radial Clearances N and R
121
Fig. 54: Measuring Clearances N and R
121
Table 42: Permissible Clearances N and R
121
Installing the Air Inlets
122
Fig. 55: Installing the Air Inlets
122
Table 43: Tightening Torque (72020)
122
Installing the Gas Outlet Flange
123
Fig. 56: Installing the Gas Outlet Flange
123
Fitting the Insulation of the Turbine Casing
124
Fig. 57: Fitting the Insulation
124
Installing the Gas Outlet Casing
125
Fig. 58: Installing the Gas Outlet Casing
125
Table 44: Tightening Torque (51009)
125
Fig. 59: Fitting the Insulation
126
Table of Tightening Torques
127
Fig. 60: Tightening Torques
127
Table 45: Tightening Torques
127
Fig. 61: Tightening Torques for Insulation
128
Table 46: Tightening Torques for Insulation
128
Taking out of Operation at Short Notice
129
Possible Emergency Repairs
129
Installing the Replacement Turbocharger
130
Installing the Replacement Cartridge Group
130
Fitting the Cover Plate
131
Fig. 62: Fitting the Cover Plate
131
Cover Plate Drawing
132
Fig. 63: Cover Plate Drawing
132
Table 47: Cover Plate Dimensions [MM]
132
Mothballing the Turbocharger
133
Taking the Engine out of Operation for up to 12 Months
133
Taking the Engine out of Operation for more than 12 Months
134
Disposing of Turbocharger Components
135
Spare Parts
136
Ordering Spare Parts
136
Required Customer Spare Part Set (97070)
136
Table 48: Customer Spare Part Set 97070
136
View of Turbocharger with Part Numbers
138
Fig. 64: Overview of Part Numbers
138
Table 49: Spare Parts List
139
View of Turbine Cleaning Device
140
Table 50: Spare Parts List
140
Tools
141
Table 51: Customer Tool Set 90000
141
Figures
142
4
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ABB A135-M55 Specifications
General
Brand
ABB
Model
A135-M55
Category
Industrial Equipment
Language
English
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