ABB A145-M65 - Page 142

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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: Weights of Turbochargers A130-M38
Removing the Turbocharger39
Fig. 6: Removing the Turbocharger39
Fig. 7: Loosening the Clamping Nut41
Fig. 8: Turbocharger Centre of Gravity42
Installing the Turbocharger43
Fig. 9: Inserting Gaskets into the Bracket43
Fig. 10: Inserting the Threaded Rods44
Fig. 11: Requirements for Threaded Rods44
Table 3: Requirements for Threaded Rods44
Fig. 12: Placing the Turbocharger on the Bracket45
Table 4: Tightening Torques for Standard Nuts46
Fig. 13: Preparing the Clamping Nut for the Tightening Procedure47
Fig. 14: Tightening Pressure Screws48
Table 5: Pressure Screw Tightening Torques48
Fig. 15: Connecting the Compressor Cooling Air Intake49
Fig. 16: Attaching the Support49
Commissioning50
Oil Supply50
Fig. 17: Oil Orifice51
Inspection Procedures52
Commissioning after Taking out of Operation54
Monitoring Operation55
Oil Pressure, Oil Temperature55
Table 6: Lubricating Oil Pressure, Oil Inlet55
Table 7: Lubricating Oil Temperature at the Inlet56
Table 8: Lubricating Oil Temperature at the Outlet56
Exhaust Gas Temperature before Turbine57
Turbocharger Speed58
Fig. 18: Layout and Overview of Speed Measurement System58
Fig. 19: Replacing the Speed Sensor60
Table 9: Tightening Torque (86505)60
Operation and Service61
Noise Emission61
Fig. 20: Noise Insulation, Bellows61
Service Work63
Fig. 21: Replacing the Protective Grid65
Expected Replacement Intervals67
Table 10: Expected Replacement Intervals67
Stopping the Engine69
Periodic Maintenance Work70
Foreword to Maintenance70
Table 11: Maintenance Table70
Cleaning the Compressor During Operation71
Fig. 22: Carrying out Wet Cleaning of Compressor74
Table 12: Parameters for Wet Cleaning of Compressor74
Cleaning the Turbine During Operation75
Table 13: Turbine Wet Cleaning, Recommended Operating State77
Fig. 23: Carrying out Wet Cleaning of Turbines78
Table 14: Wet Cleaning of Turbines, Parameters78
Cleaning Components Mechanically79
Fig. 24: Cleaning the Filter Silencer80
Fig. 25: Compressor-End, Non-Rotating Parts82
Fig. 26: Turbine End, Non-Rotating Parts83
Fig. 27: Soaking the Turbine End86
Table 15: Value Table for Soaking86
Eliminating Malfunctions89
Malfunctions When Starting89
Table 16: Malfunctions When Starting - Delayed Start-Up89
Table 17: Malfunctions When Starting - Vibrations89
Table 18: Malfunctions When Starting - Rubbing of Rotating Parts89
Malfunctions During Operation90
Table 19: Malfunctions During Operation - Lubricating Oil Pressure too Low90
Table 20: Malfunctions During Operation - Speed Reduces90
Table 21: Malfunctions During Operation - Speed Increases90
Table 22: Malfunctions During Operation - Exhaust Gas Temperature too High91
Table 23: Malfunctions During Operation - Charge Air Pressure too Low91
Table 24: Malfunctions During Operation - Charge Air Pressure too High92
Table 25: Malfunctions During Operation - Engine Performance Losses92
Turbocharger Is Surging93
Table 26: Malfunction - Turbocharger Pumping93
Table 27: Malfunction - Sporadic Surge Blows93
Malfunctions When Stopping94
Table 28: Malfunctions When Stopping - Runout Noises94
Table 29: Malfunctions When Stopping - Runout Time too Short94
Speed Measurement System95
Table 30: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude95
Table 31: Malfunction of the Speed Measurement System - Measured Speed too High95
Table 32: Malfunction of the Speed Measurement System - Measured Speed too Low95
Dismantling and Fitting96
Introduction96
Table 33: Swivel Lifting Eyes98
Table 34: Ring Nuts to be Used99
Weights of Individual Parts100
Fig. 28: Weights of Assemblies100
Table 35: Weights of Assemblies100
Removing Air Inlets101
Fig. 29: Removing Air Inlets101
Removing the Gas Outlet Casing102
Fig. 30: Removing the Insulation102
Fig. 31: Removing the Gas Outlet Casing103
Removing the Gas Outlet Flange104
Fig. 32: Dismantling the Gas Outlet Flange105
Table 36: 3 Press-Off Screws105
Fig. 33: Removing the Gas Outlet Flange106
Table 37: 6 Press-Off Screws106
Removing the Compressor Casing107
Fig. 34: Removing the Compressor Casing107
Fig. 35: Dismantling the Wall Insert108
Pressing off the Casing109
Fig. 36: Press off the Casing109
Removing the Cartridge Group110
Fig. 37: Removing Insulation Sheets110
Fig. 38: Oil Orifice110
Fig. 39: Removing Cartridge Group 1111
Fig. 40: Removing Cartridge Group 2111
Removing the Nozzle Ring112
Fig. 41: Removing the Nozzle Ring112
Installing the Cartridge Group on the Service Support113
Fig. 42: Installing the Cartridge Group on the Service Support113
Axial Clearance a and Radial Clearance B114
Fig. 43: Measuring Clearance a and B114
Table 38: Permissible Clearances a and B114
Nozzle Ring Compression PD115
Fig. 44: Nozzle Ring Compression PD115
Table 39: Permitted Nozzle Ring Compression PD115
Installing Nozzle Ring116
Fig. 45: Installing the Nozzle Ring116
Installing the Cartridge Group117
Fig. 46: Lifting the Cartridge Group and Rotating It117
Fig. 47: Installing the Cartridge Group118
Table 40: Tightening Torque (51007)118
Fig. 48: Turbine Casing Insulation / Burst Protection119
Installing the Compressor Casing120
Table 41: Tightening Torque (79041)120
Fig. 49: Installing the Compressor Casing121
Table 42: Tightening Torque (72011)121
Radial Clearances N and R122
Fig. 50: Measuring Clearances N and R122
Table 43: Permissible Clearances N and R122
Installing Air Inlets123
Fig. 51: Installing the Air Inlets123
Table 44: Tightening Torque (72020)123
Installing the Gas Outlet Flange124
Fig. 52: Installing the Gas Outlet Flange124
Fig. 53: Fitting the Insulation125
Installing the Gas Outlet Casing126
Fig. 54: Installing the Gas Outlet Casing126
Table 45: Tightening Torque (51009)126
Fig. 55: Fitting the Insulation127
Table of Tightening Torques128
Fig. 56: Tightening Torques128
Table 46: Tightening Torques128
Fig. 57: Tightening Torques for Insulation129
Table 47: Tightening Torques for Insulation129
Taking out of Operation at Short Notice130
Possible Emergency Repairs130
Installing a Replacement Turbocharger131
Installing a Replacement Cartridge Group131
Fitting the Cover Plate132
Fig. 58: Fitting the Cover Plate132
Cover Plate Drawing133
Fig. 59: Cover Plate Drawing133
Table 48: Cover Plate Dimensions [MM]133
Mothballing the Turbocharger134
Taking the Engine out of Operation for up to 12 Months134
Taking the Engine out of Operation for more than 12 Months135
Disposing of Turbocharger Components136
Spare Parts137
Ordering Spare Parts137
Required Customer Spare Part Set (97070)137
Table 49: Customer Spare Part Set 97070137
View of Turbocharger with Part Numbers138
Fig. 60: Overview of Part Numbers138
Table 50: Spare Parts List139
Figures140

ABB A145-M65 - Page 142

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