ABB A135-M55 - Page 6

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Operation Manual / 1 Introduction

1 Introduction / 1.2 Symbols, definitions

Definition of pictograms

The following pictograms can occur in this document. These point out actions that must be

taken in accordance with the meaning of the relevant pictogram.

Pictogram Meaning

Tighten with specified torque

Tighten over specified tightening angle

Hand-tight, tighten without tools

Oil

Apply screw locking paste (e.g. Loctite)

Apply high-temperature grease

Apply other paste in accordance with specifications

Oil free, grease free and dry

Affix

Measure

Note

Visually inspect

Please note text for numbered work step.

See document

Dispose of in an environmentally compatible, professional way and in compliance

with locally applicable regulations.

Table1: Definition of pictograms

Page 4 / 7

Main Page

Table of Contents3
Introduction4
Purpose of the Manual4
Symbols, Definitions5
Storage of New Turbochargers and Spare Parts7
Contact Information9
Safety12
Introduction12
CE Conformity12
Definition of Mandatory Signs13
Definition of Safety Instructions13
Intended Use14
Deflagration on Gas Engines15
Warning Plates on the Turbocharger16
Turbocharger Rating Plate17
Periodic Check of the Pressure Vessels18
Lifting of Loads19
Prerequisites for Operation and Maintenance20
Hazards During Operation and Maintenance21
Safe Operation23
Safe Maintenance25
Introduction33
Essential Information33
Registered Trademarks33
Related Documents33
Table 1: Related Documents33
Layout and Function of the Turbocharger34
Fig. 1: Layout and Function of the Turbocharger34
Fig. 2: Compressor Wheel Cooling35
Warning Plates on the Turbocharger36
Fig. 3: Warning Plate Locations36
Locations of the Rating Plates37
Fig. 4: Locations of the Rating Plates37
Removing and Installing38
Turbocharger Weight and Transportation38
Fig. 5: Suspension of Complete Turbocharger Unit38
Table 2: Weight of Complete Turbocharger Unit38
Removing the Turbocharger39
Fig. 6: Turbine Cleaning Nozzle39
Fig. 7: Removing the Turbocharger40
Fig. 8: Loosening the Clamping Nut42
Fig. 9: Turbocharger Centre of Gravity43
Installing the Turbocharger44
Fig. 10: Inserting Gaskets into the Bracket44
Fig. 11: Inserting the Threaded Rods45
Fig. 12: Requirements for Threaded Rods45
Table 3: Requirements for Threaded Rods45
Fig. 13: Placing the Turbocharger on the Bracket46
Table 4: Tightening Torque for Standard Nuts47
Fig. 14: Preparing the Clamping Nut for the Tightening Procedure48
Fig. 15: Tightening Pressure Screws49
Table 5: Torque-Controlled Tightening of the Pressure Screws49
Fig. 16: Connecting the Speed Sensor50
Fig. 17: Connecting the Compressor Cooling Air Intake50
Fig. 18: Attaching the Support51
Commissioning52
Oil Supply52
Fig. 19: Oil Orifice53
Inspection Procedures54
Commissioning after Taking out of Operation56
Monitoring Operation57
Oil Pressure, Oil Temperature57
Table 6: Lubricating Oil Pressure at Oil Inlet before Turbocharger57
Table 7: Lubricating Oil Temperature at the Inlet58
Table 8: Lubricating Oil Temperature at the Outlet58
Exhaust Gas Temperature before Turbine59
Turbocharger Speed60
Fig. 20: Layout and Overview of Speed Measurement System60
Fig. 21: Replacing the Speed Sensor62
Table 9: Tightening Torque (86505)62
Operation and Service63
Noise Emission63
Fig. 22: Noise Insulation, Bellows64
Service Work65
Fig. 23: Replacing the Protective Grid67
Expected Replacement Intervals69
Table 10: Expected Replacement Intervals69
Stopping the Engine71
Periodic Maintenance Work72
Foreword to Maintenance72
Table 11: Maintenance Table72
Cleaning the Compressor During Operation73
Fig. 24: Carrying out Wet Cleaning of Compressor75
Table 12: Parameters for Wet Cleaning of Compressor75
Cleaning the Turbine During Operation76
Table 13: Turbine Wet Cleaning, Recommended Operating State78
Fig. 25: Carrying out Wet Cleaning of Turbine79
Table 14: Wet Cleaning of Turbine, Parameters79
Cleaning Components Mechanically80
Fig. 26: Cleaning the Filter Silencer81
Fig. 27: Compressor-End, Non-Rotating Parts83
Fig. 28: Turbine End, Non-Rotating Parts85
Fig. 29: Soaking the Turbine End87
Table 15: Value Table for Soaking87
Eliminating Malfunctions90
Malfunctions When Starting90
Table 16: Malfunctions When Starting - Delayed Start-Up90
Table 17: Malfunctions When Starting - Vibrations90
Table 18: Malfunctions When Starting - Rubbing of Rotating Parts90
Malfunctions During Operation91
Table 19: Malfunctions During Operation - Lubricating Oil Pressure too Low91
Table 20: Malfunctions During Operation - Speed Reduces91
Table 21: Malfunctions During Operation - Speed Increases91
Table 22: Malfunctions During Operation - Exhaust Gas Temperature too High92
Table 23: Malfunctions During Operation - Charge Air Pressure too Low92
Table 24: Malfunctions During Operation - Charge Air Pressure too High93
Table 25: Malfunctions During Operation - Engine Performance Losses93
Turbocharger Is Surging94
Table 26: Malfunction - Turbocharger Pumping94
Table 27: Malfunction - Sporadic Surge Blows94
Malfunctions When Stopping95
Table 28: Malfunctions When Stopping - Runout Noises95
Table 29: Malfunctions When Stopping - Runout Time too Short95
Speed Measurement System96
Table 30: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude96
Table 31: Malfunction of the Speed Measurement System - Measured Speed too High96
Table 32: Malfunction of the Speed Measurement System - Measured Speed too Low96
Dismantling and Fitting97
Introduction97
Material Required98
Fig. 30: Swivel Lifting Eyes98
Table 33: Swivel Lifting Eyes98
Weights of Individual Parts99
Fig. 31: Starpoint Ring Nut VRM99
Fig. 32: Weights of Assemblies100
Table 34: Weights of Assemblies100
Removing the Air Inlets101
Fig. 33: Removing the Air Inlets101
Removing the Gas Outlet Casing102
Fig. 34: Removing the Insulation102
Removing the Gas Outlet Flange103
Fig. 35: Removing the Gas Outlet Casing103
A130 A135 A140 A145104
Fig. 36: Dismantling the Gas Outlet Flange104
Table 35: 3 Press-Off Screws104
Fig. 37: Removing the Gas Outlet Flange105
Table 36: 6 Press-Off Screws105
Removing the Compressor Casing106
Compressor Casing106
Fig. 38: Removing the Compressor Casing106
Wall Insert107
Fig. 39: Dismantling the Wall Insert107
Pressing off the Casing108
Fig. 40: Press off the Casing108
Removing the Cartridge Group109
Cartridge Group109
Fig. 41: Removing Insulation Sheets109
Fig. 42: Oil Orifice109
Fig. 43: Removing Cartridge Group 1110
Fig. 44: Removing Cartridge Group 2110
Removing the Nozzle Ring111
Nozzle Ring111
Burst Ring111
Fig. 45: Removing the Nozzle Ring111
Installing the Cartridge Group on the Service Support112
Fig. 46: Installing the Cartridge Group on the Service Support112
Measuring Clearance a and B113
Fig. 47: Measuring Clearance a and B113
Table 37: Permissible Clearances a and B113
Nozzle Ring Compression PD114
Fig. 48: Nozzle Ring Compression PD114
Table 38: Nozzle Ring Compression PD114
Installing the Nozzle Ring115
Fig. 49: Installing the Nozzle Ring115
Installing the Cartridge Group116
Fig. 50: Lifting the Cartridge Group and Rotating It116
Fig. 51: Installing the Cartridge Group116
Table 39: Tightening Torque (51007)117
Fig. 52: Turbine Casing Insulation / Burst Protection118
Installing the Compressor Casing119
Table 40: Tightening Torque (79041)119
Fig. 53: Installing the Compressor Casing120
Table 41: Tightening Torque (72011)120
Measuring Radial Clearances N and R121
Fig. 54: Measuring Clearances N and R121
Table 42: Permissible Clearances N and R121
Installing the Air Inlets122
Fig. 55: Installing the Air Inlets122
Table 43: Tightening Torque (72020)122
Installing the Gas Outlet Flange123
Fig. 56: Installing the Gas Outlet Flange123
Fitting the Insulation of the Turbine Casing124
Fig. 57: Fitting the Insulation124
Installing the Gas Outlet Casing125
Fig. 58: Installing the Gas Outlet Casing125
Table 44: Tightening Torque (51009)125
Fig. 59: Fitting the Insulation126
Table of Tightening Torques127
Fig. 60: Tightening Torques127
Table 45: Tightening Torques127
Fig. 61: Tightening Torques for Insulation128
Table 46: Tightening Torques for Insulation128
Taking out of Operation at Short Notice129
Possible Emergency Repairs129
Installing the Replacement Turbocharger130
Installing the Replacement Cartridge Group130
Fitting the Cover Plate131
Fig. 62: Fitting the Cover Plate131
Cover Plate Drawing132
Fig. 63: Cover Plate Drawing132
Table 47: Cover Plate Dimensions [MM]132
Mothballing the Turbocharger133
Taking the Engine out of Operation for up to 12 Months133
Taking the Engine out of Operation for more than 12 Months134
Disposing of Turbocharger Components135
Spare Parts136
Ordering Spare Parts136
Required Customer Spare Part Set (97070)136
Table 48: Customer Spare Part Set 97070136
View of Turbocharger with Part Numbers138
Fig. 64: Overview of Part Numbers138
Table 49: Spare Parts List139
View of Turbine Cleaning Device140
Table 50: Spare Parts List140
Tools141
Table 51: Customer Tool Set 90000141
Figures142

ABB A135-M55 - Page 6

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