ABB HT596782 - Page 108

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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 Maintenance24
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
Position of the Rating Plate35
Fig. 2: Position of the Rating Plate35
Warning Plates on the Turbocharger36
Fig. 3: Warning Plates on the Turbocharger36
Removing and Installing37
Turbocharger Weight and Transportation37
Fig. 4: Turbocharger Transport37
Table 2: Weight of the Turbocharger37
Table 3: Swivel Lifting Eye (S) to be Used37
Table 30: Swivel Lifting Eye (S) to be Used37
Removing the Turbocharger38
Fig. 5: Removing the Turbocharger39
Installing the Turbocharger40
Fig. 6: Inserting O-Rings into Bracket40
Fig. 7: Inserting Threaded Rods into the Bracket41
Fig. 8: Requirements for Threaded Rods41
Table 4: Requirements for Threaded Rods41
Fig. 9: Placing the Turbocharger on the Bracket42
Table 5: Tightening Torque for Turbocharger Fixing Screws42
Commissioning43
Oil Supply43
Inspection Procedures44
Commissioning after Taking out of Operation46
Monitoring Operation47
Oil Pressure, Oil Temperature47
Table 6: Lubricating Oil Pressure at Oil Inlet before Turbocharger47
Table 7: Lubricating Oil Temperature at the Inlet48
Table 8: Lubricating Oil Temperature at the Outlet48
Exhaust Gas Temperature before Turbine49
Turbocharger Speed49
Fig. 10: Layout and Overview of the Speed Measurement System50
Fig. 11: Fitting the Speed Sensor52
Table 9: Tightening Torque (86505)52
Operation and Service53
Noise Emission53
Fig. 12: Noise Insulation, Bellows54
Service Work55
Expected Replacement Intervals58
Table 10: Expected Replacement Intervals [H]58
Stopping the Engine59
Periodic Maintenance Work60
Foreword to Maintenance60
Cleaning Components Mechanically60
Table 11: Maintenance Table60
Fig. 13: Cleaning the Filter Silencer61
Fig. 14: Cleaning the Compressor Casing, Diffuser Mechanically63
Fig. 15: Cleaning the Nozzle Ring, Turbine Casing Mechanically64
Fig. 16: Soaking Contamination of the Turbine66
Table 12: Dimensions of the Cleaning Container66
Eliminating Malfunctions69
Malfunctions When Starting69
Table 13: Malfunctions When Starting - Delayed Start-Up69
Table 14: Malfunctions When Starting - Vibrations69
Table 15: Malfunctions When Starting - Rotating Parts Rubbing69
Malfunctions During Operation70
Table 16: Malfunctions During Operation - Lubricating Oil Pressure too Low70
Table 17: Malfunctions During Operation - Speed Reduces70
Table 18: Malfunctions During Operation - Speed Increases70
Table 19: Malfunctions During Operation - Exhaust Gas Temperature too High71
Table 20: Malfunctions During Operation - Charge Air Pressure too Low71
Table 21: Malfunctions During Operation - Charge Air Pressure too High72
Table 22: Malfunctions During Operation - Engine Performance Losses72
Turbocharger Is Surging73
Table 23: Malfunction - Turbocharger Pumping73
Table 24: Malfunction - Sporadic Surge Blows73
Malfunctions When Stopping74
Table 25: Malfunctions When Stopping - Runout Noises74
Table 26: Malfunctions When Stopping - Runout Time too Short74
Speed Measurement System75
Table 27: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude75
Table 28: Malfunction of the Speed Measurement System - Measured Speed too High75
Table 29: Malfunction of the Speed Measurement System - Measured Speed too Low75
Dismantling and Fitting76
Introduction76
Table 31: Ring Nuts to be Used79
Weights of Individual Parts80
Fig. 17: Overview of Assemblies80
Table 32: Weights of the Assemblies [Kg]80
Removing the Gas Outlet Casing81
Fig. 18: Removing the Gas Outlet Casing81
Removing Air Inlets82
Fig. 19: Removing the Air Inlets82
Removing the Compressor Casing83
Fig. 20: Removing the Compressor Casing (1/2)83
Fig. 21: Removing the Compressor Casing (2/2)84
Removing the Cartridge Group85
Fig. 22: Do Not Loosen Screw Plugs85
Fig. 23: Removing the Cartridge Group (1)86
Fig. 24: Removing Cartridge Group 287
Fig. 25: Rotating the Cartridge Group and Fitting the Service Support87
Removing Nozzle Ring88
Fig. 26: Removing the Nozzle Ring88
Axial Clearance a and Radial Clearance B89
Fig. 27: Measuring Clearance a and B89
Table 33: Permissible Clearances a and B89
Nozzle Ring Compression PD90
Fig. 28: Measuring Nozzle Ring Compression90
Table 34: Permitted Nozzle Ring Compression PD90
Fitting the Diffuser91
Fig. 29: Fitting the Diffuser91
Table 35: Tightening Torque (72041)91
Installing the Cartridge Group92
Fig. 30: Lifting the Cartridge Group and Rotating It92
Fig. 31: Fitting the Cartridge Group93
Table 36: Tightening Torque (72011)93
Installing Nozzle Ring94
Fig. 32: Installing the Nozzle Ring94
Fitting the Turbine Casing95
Fig. 33: Fitting the Turbine Casing95
Table 37: Tightening Torque (51007)95
Rotating the Turbocharger96
Fig. 34: Rotating the Turbocharger96
Radial Clearances N and R97
Fig. 35: Measuring Clearances N and R97
Table 38: Permissible Clearances N and R97
Installing the Gas Outlet Casing98
Fig. 36: Fitting the Gas Outlet Casing98
Table 39: Tightening Torque (51101)98
Installing Air Inlets99
Fig. 37: Installing the Air Inlets99
Table 40: Tightening Torque (72020)99
Table of Tightening Torques100
Fig. 38: Overview of Tightening Torques100
Table 41: Overview of Tightening Torques100
Taking out of Operation at Short Notice101
Possible Emergency Repairs101
Mothballing the Turbocharger102
Taking the Engine out of Operation for up to 12 Months102
Taking the Engine out of Operation for more than 12 Months103
Disposing of Turbocharger Components104
Spare Parts105
Spare Part Overview105
Ordering Spare Parts105
Figures106

ABB HT596782 - Page 108

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