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ABB HT596622 User Manual
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Operation Manual / A170-M.. - A175-M..
1 Introduction / 1.5 Layout and function of the turbocharger
© Copyright 2022 ABB. All rights reserved.
HZTL4033_EN
Rev.K
January 2022
1.5
Layout and function of the turbocharger
Fig.2: Layout and function
01
Filter silencer / air suction branch
06
Gas inlet casing
02
Compressor wheel
07
Nozzle ring
03
Diffuser
08
Turbine
04
Bearing bush
09
Bearing casing
05
Gas outlet casing
10
Compressor casing
Page 6 / 146
7
9
Table of Contents
Operation Manual / A170-M - A175-M
3
Table of Contents
3
Operation Manual / A170-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
Registered Trademarks
7
Layout and Function of the Turbocharger
8
Fig. 2: Layout and Function
8
Fig. 3: Connection of the Compressor Wheel Cooling
9
Symbols, Definitions
10
Table 1: Definition of Pictograms
11
Fig. 4: Volatile Corrosion Inhibitor (VCI)
12
Storage of New Turbochargers and Spare Parts
12
Fig. 5: Package with Hygrometer
13
Safety
14
Introduction
14
CE Conformity
14
Definition of Mandatory Signs
15
Definition of Safety Instructions
15
Table 2: Personal Protective Equipment to be Worn at All Times
15
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
15
Intended Use
16
Deflagration on Gas Engines
17
Periodic Check of the Pressure Vessels
17
Warning Plates on the Turbocharger
18
Fig. 6: Warning Plates on the Turbocharger
18
Fig. 7: Rating Plate
19
Turbocharger Rating Plate
19
Fig. 8: Locations of the Rating Plates
20
Lifting of Loads
21
Fig. 9: Attachment of Loads on the Crane Hook
21
Fig. 10: Attachment Angle
21
Prerequisites for Operation and Maintenance
22
Hazards During Operation and Maintenance
23
Safe Operation
25
Safe Maintenance
26
Removal and Installation
30
Turbocharger Weight
30
Fig. 11: Turbocharger Suspension Points
30
Table 4: Weight of Complete Turbocharger Unit
30
Fig. 12: Turbocharger Suspension Points
31
Removing the Turbocharger
31
Fig. 13: Removing the Foot Mounting
32
Fig. 14: Loosening the Clamping Nut
33
Installing the Turbocharger
34
Fig. 15: Turbocharger Suspension Points
34
Fig. 16: Removing Auxiliary Screw
35
Fig. 17: Compressor-End Foot
35
Fig. 18: Turbine-End Foot
36
Table 5: Foot Screws, Dimension and Strength Class
36
Table 6: Foot Screws, Dimension CE
36
Table 7: Foot Screws, Dimension te
36
Table 8: Foot Screws, Number of Cup Springs
36
Fig. 19: CE Foot Contact Surface
37
Fig. 20: te Foot: Handling of Cup Spring Contact Surface / Foot Contact Surface
37
Fig. 21: Tightening the Foot Screws (1)
38
Fig. 22: Tightening Procedure
39
Table 9: Torque-Controlled Tightening of the Pressure Screws
39
Commissioning
40
Oil Supply
40
Inspection Procedures
41
Commissioning after Taking out of Operation
42
Monitoring During Operation
43
Oil Pressure, Oil Temperature
43
Fig. 23: Lubricating Oil Pressure Measuring Point
43
Table 10: Oil Pressure Range
43
Table 11: Oil Temperature at the Inlet
44
Table 12: Oil Temperature at the Outlet
44
Turbocharger Speed
45
Fig. 24: Speed Measurement
45
Noise Emission
48
Operation and Service
48
Fig. 25: Noise Insulation, Bellows
49
Service Work
50
Expected Replacement Intervals
53
Stopping the Engine
54
Table 13: Expected Replacement Intervals
54
Table 14: Recommended Replacement Intervals
54
Periodic Maintenance
55
Foreword to Maintenance
55
Cleaning the Filter Silencer
56
Fig. 26: Cleaning the Filter Silencer
56
Fig. 27: Cleaning the Filter Silencer (2)
58
Table 15: Tightening Torque (81272)
58
Table 16: Tightening Torque (81273)
58
Cleaning the Slotted Diffuser
59
Fig. 28: Cleaning the Slotted Diffuser
59
Cleaning the Compressor During Operation
60
Table 17: Compressor Cleaning Parameters
62
Fig. 29: Operation of Water Pressure Vessel
64
Table 18: Compressor Cleaning Parameters
65
Cleaning Turbine and Nozzle Ring
66
Fig. 30: Turbine and Nozzle Ring Cleaning Cycle
68
Fig. 31: Cleaning Cycle of Turbine and Nozzle Ring with Load Ramp
69
Fig. 32: Procedure Wet Cleaning of Turbine and Nozzle Ring
70
Table 19: Cleaning Parameters Wet Cleaning of Turbine and Nozzle Ring
71
Table 21: Malfunctions When Starting - Vibrations
72
Table 22: Malfunctions When Starting - Rubbing of Rotating Parts
72
Table 20: Malfunctions When Starting - Delayed Start-Up
72
Malfunctions When Starting
72
Troubleshooting
72
Malfunctions During Operation
73
Table 23: Malfunctions During Operation - Lubricating Oil Pressure too Low
73
Table 24: Malfunctions During Operation - Drop in Speed
73
Table 25: Malfunctions During Operation - Speed Increases
73
Table 26: Malfunctions During Operation - Exhaust Gas Temperature too High
74
Table 27: Malfunctions During Operation - Charge Air Pressure too Low
74
Surging of the Turbocharger
75
Table 28: Malfunctions During Operation - Charge Air Pressure too High
75
Table 29: Surging of the Turbocharger
75
Malfunctions When Stopping
76
Table 30: Malfunctions When Stopping - Runout Noises
76
Table 31: Malfunctions When Stopping - Shortened Runout Time
76
Table 34: Malfunction, Measured Speed too Low
77
Table 33: Malfunction, Measured Speed too High
77
Table 32: Malfunction, no Speed Measurement Signal or Poor Signal Amplitude
77
Speed Measurement System
77
Disassembly and Assembly
78
Introduction
78
Weight of Assemblies
80
Fig. 33: Weight of Assemblies
80
Table 35: Assembly Weights
80
Removing the Air Inlets
81
Fig. 34: Removing the Filter Silencer
81
Fig. 35: Removing the Air Suction Branch
82
Axial Clearance a Prior to Disassembly
83
Fig. 36: Axial Clearance
83
Table 36: Axial Clearance a
83
Fig. 37: Removing Wall Insert
84
Removing the Compressor Casing
84
Fig. 38: Transporting and Turning Wall Insert
85
Fig. 39: Removing the Diffuser
86
Fig. 40: Removing the Compressor Casing
87
Removing the Cartridge Group
88
Fig. 41: Safety-Relevant Screws
88
Fig. 42: Removing Cartridge Group 1
89
Fig. 43: Removing Cartridge Group 2
90
Removing the Nozzle Ring
91
Fig. 44: Removing Turbine Diffuser 1
91
Fig. 45: Removing Turbine Diffuser 2
92
Fig. 46: Removing Cover Ring 1
93
Fig. 47: Removing Cover Ring 2
94
Fig. 48: Removing Nozzle Ring 1
94
Fig. 49: Removing Nozzle Ring 2
95
Installing the Nozzle Ring
96
Fig. 50: Installing Nozzle Ring 1
96
Fig. 51: Installing Nozzle Ring 2
97
Table 37: Tightening Torque (56014)
97
Fig. 52: Installing Cover Ring
98
Table 38: Tightening Torque (57005)
98
Fig. 53: Installing Turbine Diffuser 1
99
Fig. 54: Installing Turbine Diffuser 2
100
Table 39: Tightening Torque (61069)
100
Installing the Cartridge Group
101
Fig. 55: Installing the Cartridge Group 1
101
Fig. 56: Installing the Cartridge Group 2
102
Fig. 57: Installing the Cartridge Group 3
102
Table 40: Tightening Torque (61059 / 42128)
102
Table 41: Tightening Torque (86505)
103
Fitting the Spinner Nose Cone
104
Fig. 58: Preparing the Threaded Stud (25008)
104
Table 42: Inner Thread Size (25008)
104
Fig. 59: Fitting the Spinner Nose Cone (25012)
105
Table 43: Tightening Torque (25013)
105
Installing the Compressor Casing
106
Fig. 60: Installing the Compressor Casing
106
Table 44: Tightening Torque (61037)
106
Table 45: Tightening Torque, Nuts that Are Difficult
106
Table 46: Tightening Torque (61090)
106
Fig. 61: Installing Diffuser
107
Table 47: Tightening Torque (77015)
107
Fig. 62: Turning and Moving in Wall Insert
108
Table 48: Tightening Torque (72011)
109
Fig. 63: Fitting Wall Insert
109
Axial Clearance a after Assembly
110
Fig. 64: Axial Clearance
110
Table 49: Axial Clearance a
110
Installing the Air Inlets
111
Fig. 65: Installing the Air Suction Branch
111
Table 50: Tightening Torque (72027)
111
Fig. 66: Installing the Filter Silencer
112
Table 51: Tightening Torque (72027)
112
Removing and Installing Turbine-End Nozzle Ring
114
Fig. 67: Removing the Nozzle Ring at the Turbine End (Radial Gas Inlet Casing)
115
Fig. 68: Removing the Nozzle Ring at the Turbine End (Axial Gas Inlet Casing)
115
Fig. 69: Installing the Nozzle Ring at the Turbine End (Radial Gas Inlet Casing)
116
Fig. 70: Installing the Nozzle Ring at the Turbine End (Axial Gas Inlet Casing)
116
Table 52: Tightening Torque (56014)
117
Table 53: Tightening Torque (61009)
117
Table of Tightening Torques
118
Fig. 71: Tightening Torques 1
118
Fig. 72: Tightening Torques 2
118
Table 54: Tightening Torques
119
Fig. 73: Flange Tightening Sequence
120
Table 55: Tightening Torques 61009
120
Taking a Turbocharger out of Operation
121
Possible Emergency Repairs
121
Locking the Rotor
122
Fig. 74: Fitting the Locking Device
123
Table 56: Locking Device Tightening Torque
123
Table 59: Cover Plate Dimensions 3
125
Table 58: Cover Plate Dimensions 2
125
Fig. 76: Fitting the Cover Plate
125
Table 57: Cover Plate Dimensions 1
125
Fig. 75: Cover Plate (01) / Spacer Sleeves (02) Dimensions
125
Fitting the Cover Plate
125
Blanking off the Inlets and Outlets
127
Engines with Bypass Around the Turbocharger
127
Mothballing the Turbocharger
128
Taking the Engine out of Operation for up to 12 Months
128
Taking the Engine out of Operation for more than 12 Months
129
Material and Disposal
130
REACH and Rohs Compliance Declaration for Products
130
Disposing of Turbocharger Components
131
Spare Parts
132
Ordering Spare Parts
132
Table 60: Customer Spare Part Set (97070)
132
Spare Part - Illustrations
133
Table 61: Spare Parts - Cartridge
133
Table 62: Spare Parts - Bearing Casing
134
Table 63: Spare Parts - Rotor and Bearing Parts
135
Table 64: Spare Parts - Water Vessel
136
Table 65: Spare Parts - Gas Inlet Casing Axial
137
Table 66: Spare Parts - Gas Inlet Casing Radial
138
Table 67: Spare Parts - Cleaning Device for Gas Inlet Casing
139
Table 68: Spare Parts - Compressor Casing
140
Table 69: Spare Parts - Filter Silencer
141
Table 70: Spare Parts - Air Suction Branch Radial
142
Tools
143
Table 71: Customer Tool Set 90009
143
Figures
145
Tables
147
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Original Operation Manual
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ABB HT596622 Specifications
General
Brand
ABB
Model
HT596622
Category
Industrial Equipment
Language
English
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