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A135-M65
ABB A135-M65 User Manual
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Operation Manual /
1 Introduction
T
able of contents
Page
1
/
8
© Copyright
2016 ABB.
All r
ights re
served.
HZTL4005_EN
Revision E
July 2016
Intro
duction
1
Introduction
.....................
..............................................
.........................
3
1.1
Purpose of the m
anual
................................................................
...............
3
1.2
Symbols, definitions
................................................................
...................
4
1.3
Storage of new turbochargers and spare pa
rts
................................
..........
6
1.4
Contact information
................................
....................................................
8
2
4
Table of Contents
Introduction
3
Table of Contents
3
Introduction
5
Purpose of the Manual
5
July
5
Symbols, Definitions
6
Storage of New Turbochargers and Spare Parts
8
Contact Information
10
Safety
11
CE Conformity
13
Introduction
13
Safety
13
Definition of Mandatory Signs
14
Definition of Safety Instructions
14
Intended Use
15
Deflagration on Gas Engines
16
Warning Plates on the Turbocharger
17
Turbocharger Rating Plate
18
Periodic Check of the Pressure Vessels
19
Lifting of Loads
20
Prerequisites for Operation and Maintenance
21
Hazards During Operation and Maintenance
22
Safe Operation
24
Safe Maintenance
26
Product Description
33
Default Chapter
33
Table 10 Expected Replacement Intervals
33
Table 16 Malfunctions When Starting
33
Table of Contents
33
Table 19 Malfunctions During Operation
34
Table 28 Malfunctions When Stopping
34
1 Introduction
37
Essential Information
37
Registered Trademarks
37
Related Documents
37
Table 1 Related Documents
37
Layout and Function of the Turbocharger
38
Warning Plates on the Turbocharger
40
Locations of the Rating Plates
41
2 Removing and Installing
43
Turbocharger Weight and Transportation
43
Table 2 Weights of Turbochargers A130
43
Removing the Turbocharger
44
Installing the Turbocharger
48
Table 3 Requirements for Threaded Rods
49
Table 4 Tightening Torques for Standard
51
Table 5 Pressure Screw Tightening Tor
53
3 Commissioning
55
Oil Supply
55
Inspection Procedures
57
Commissioning after Taking out of Operation
59
4 Monitoring Operation
61
Oil Pressure, Oil Temperature
61
Table 6 Lubricating Oil Pressure, Oil Inlet
61
Table 7 Lubricating Oil Temperature at the Inlet
62
Table 8 Lubricating Oil Temperature at the Outlet
62
Exhaust Gas Temperature before Turbine
63
Turbocharger Speed
64
Table 9 Tightening Torque
66
5 Operation and Service
67
Noise Emission
67
Service Work
69
Expected Replacement Intervals
73
Stopping the Engine
75
6 Periodic Maintenance Work
77
Foreword to Maintenance
77
Table 11 Maintenance Table
77
Cleaning the Compressor During Operation
78
Table 12 Parameters for Wet Cleaning of
81
Cleaning the Turbine During Operation
82
Table 13: Turbine Wet Cleaning, Recommended Operating State
84
Table 14 Wet Cleaning of Turbines, Pa
85
Cleaning Components Mechanically
86
Table 15 Value Table for Soaking
93
7 Eliminating Malfunctions
97
Malfunctions When Starting
97
Table 17 Malfunctions When Starting
97
Table 18 Malfunctions When Starting - Rubbing of Rotating Parts
97
Malfunctions During Operation
98
Table 20 Malfunctions During Operation - Speed Reduces
98
Table 21 Malfunctions During Operation - Speed Increases
98
Table 22 Malfunctions During Operation
99
Table 23 Malfunctions During Operation - Charge Air Pressure too Low
99
Table 24 Malfunctions During Operation - Charge Air Pressure too High
100
Table 25 Malfunctions During Operation - Engine Performance Losses
100
Turbocharger Is Surging
101
Table 26 Malfunction - Turbocharger
101
Table 27 Malfunction - Sporadic Surge Blows
101
Malfunctions When Stopping
102
Table 29 Malfunctions When Stopping - Runout Time too Short
102
Speed Measurement System
103
Table 30 Malfunction of the Speed Meas
103
Table 31 Malfunction of the Speed Meas
103
Table 32 Malfunction of the Speed Meas
103
8 Dismantling and Fitting
105
Introduction
105
Table 33 Swivel Lifting Eyes
107
Table 34 Ring Nuts to be Used
108
Weights of Individual Parts
109
Table 35 Weights of Assemblies
109
Removing Air Inlets
110
Removing the Gas Outlet Casing
111
Removing the Gas Outlet Flange
113
Table 36 3 Press-Off Screws
114
Table 37 6 Press-Off Screws
115
Removing the Compressor Casing
116
Pressing off the Casing
118
Removing the Cartridge Group
119
Removing the Nozzle Ring
121
Installing the Cartridge Group on the Service Support
122
Axial Clearance a and Radial Clearance B
123
Table 38 Permissible Clearances a and B
123
Nozzle Ring Compression PD
124
Table 39: Permitted Nozzle Ring Compression PD
124
Installing Nozzle Ring
125
Installing the Cartridge Group
126
Table 40 Tightening Torque (51007)
127
Installing the Compressor Casing
129
Table 41 Tightening Torque (79041)
129
Table 42 Tightening Torque (72011)
130
Radial Clearances N and R
131
Table 43 Permissible Clearances N and R
131
Installing Air Inlets
132
Table 44 Tightening Torque (72020)
132
Installing the Gas Outlet Flange
133
Installing the Gas Outlet Casing
135
Table 45 Tightening Torque (51009)
135
Table of Tightening Torques
137
Table 46 Tightening Torques
137
Table 47 Tightening Torques for Insulation
138
9 Taking out of Operation at Short Notice
139
Possible Emergency Repairs
139
Installing a Replacement Turbocharger
140
Installing a Replacement Cartridge Group
140
Fitting the Cover Plate
141
Cover Plate Drawing
142
Table 48 Cover Plate Dimensions [MM]
142
10 Mothballing the Turbocharger
143
Taking the Engine out of Operation for up to 12 Months
143
Taking the Engine out of Operation for more than 12 Months
144
11 Disposing of Turbocharger Components
145
12 Spare Parts
147
Ordering Spare Parts
147
Required Customer Spare Part Set (97070)
147
Table 49 Customer Spare Part Set 97070
147
View of Turbocharger with Part Numbers
148
Table 50 Spare Parts List
149
Figures
151
Tables
153
5
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ABB A135-M65 Specifications
General
Brand
ABB
Model
A135-M65
Category
Battery Charger
Language
English
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