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HT604133
ABB HT604133 Original Operation Manual
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Operation Manual / 1 Introduction
1 Introduction / 1.4 Contact information
© Copyright 2020 ABB. All rights reserved.
HZTL4005_EN
Rev.G
March 2020
1.4
Contact information
Contact information for the ABB Turbocharging Service Stations is available online.
u
Scan the QR code to access our website.
ABB Switzerland Ltd, Turbocharging
Bruggerstrasse 71a
CH-5401 Baden
Switzerland
www.abb.com/turbocharging
Page 7 / 7
8
10
Table of Contents
Introduction
3
Table of Contents
3
Introduction
4
Purpose of the Manual
4
Symbols, Definitions
5
Storage of New Turbochargers and Spare Parts
7
Contact Information
9
Safety
11
CE Conformity
12
Introduction
12
Safety
12
Definition of Mandatory Signs
13
Definition of Safety Instructions
13
Intended Use
14
Deflagration on Gas Engines
15
Warning Plates on the Turbocharger
16
Turbocharger Rating Plate
17
Periodic Check of the Pressure Vessels
18
Lifting of Loads
19
Prerequisites for Operation and Maintenance
20
Hazards During Operation and Maintenance
21
Safe Operation
23
Safe Maintenance
25
Product Description
31
Essential Information
33
Introduction
33
Registered Trademarks
33
Related Documents
33
Table 1: Related Documents
33
Fig. 1: Layout and Function of the Turbocharger
34
Layout and Function of the Turbocharger
34
Fig. 2: Compressor Wheel Cooling
35
Fig. 3: Warning Plate Locations
36
Warning Plates on the Turbocharger
36
Fig. 4: Locations of the Rating Plates
37
Locations of the Rating Plates
37
Fig. 5: Transportation of the Turbocharger
38
Removing and Installing
38
Table 2: Weight of Complete Turbocharger Unit
38
Weight and Transportation of the Turbocharger
38
Fig. 6: Removing the Turbocharger
39
Removing the Turbocharger
39
Fig. 7: Loosening the Clamping Nut
41
Fig. 8: Putting down the Turbocharger
42
Fig. 9: Inserting Gaskets into the Bracket
43
Installing the Turbocharger
43
Fig. 10: Fitting Threaded Rods Onto the Bracket
44
Fig. 11: Requirements for Threaded Rods
44
Table 3: Requirements for Threaded Rods
44
Fig. 12: Placing the Turbocharger on the Bracket
45
Table 4: Tightening Torque for Standard Nuts
46
Fig. 13: Preparing the Clamping Nut for the Tightening Procedure
47
Fig. 14: Tightening Pressure Screws
48
Table 5: Torque-Controlled Tightening of the Pressure Screws
48
Fig. 15: Connecting the Compressor Cooling Air Intake
49
Fig. 16: Attaching the Support
49
Commissioning
50
Oil Supply
50
Fig. 17: Oil Orifice
51
Inspection Procedures
52
Commissioning after Taking out of Operation
54
Monitoring Operation
55
Oil Pressure, Oil Temperature
55
Table 6: Lubricating Oil Pressure at Oil Inlet before Turbocharger
55
Table 7: Lubricating Oil Temperature at the Inlet
56
Table 8: Lubricating Oil Temperature at the Outlet
56
Exhaust Gas Temperature before Turbine
57
Fig. 18: Layout and Overview of Speed Measurement System
58
Turbocharger Speed
58
Fig. 19: Replacing the Speed Sensor
60
Table 9: Tightening Torque (86505)
60
Noise Emission
61
Operation and Service
61
Fig. 20: Noise Insulation, Bellows
62
Service Work
63
Fig. 21: Replacing the Protective Grid
65
Expected Replacement Intervals
67
Table 10: Expected Replacement Intervals
68
Stopping the Engine
69
Foreword to Maintenance
70
Periodic Maintenance Work
70
Table 11: Maintenance Table
70
Cleaning Components Mechanically
71
Fig. 22: Cleaning the Filter Silencer
72
Fig. 23: Compressor-End, Non-Rotating Parts
74
Fig. 24: Turbine End, Non-Rotating Parts
75
Fig. 25: Soaking the Turbine End
78
Table 12: Value Table for Soaking
78
Eliminating Malfunctions
81
Malfunctions When Starting
81
Table 13: Malfunctions When Starting - Delayed Start-Up
81
Table 14: Malfunctions When Starting - Vibrations
81
Table 15: Malfunctions When Starting - Rubbing of Rotating Parts
81
Malfunctions During Operation
82
Table 16: Malfunctions During Operation - Lubricating Oil Pressure too Low
82
Table 17: Malfunctions During Operation - Speed Reduces
82
Table 18: Malfunctions During Operation - Speed Increases
82
Table 19: Malfunctions During Operation - Exhaust Gas Temperature too High
83
Table 20: Malfunctions During Operation - Charge Air Pressure too Low
83
Table 21: Malfunctions During Operation - Charge Air Pressure too High
84
Table 22: Malfunctions During Operation - Engine Performance Losses
84
Table 23: Malfunction - Turbocharger Pumping
85
Table 24: Malfunction - Sporadic Surge Blows
85
Turbocharger Is Surging
85
Malfunctions When Stopping
86
Table 25: Malfunctions When Stopping - Runout Noises
86
Table 26: Malfunctions When Stopping - Runout Time too Short
86
Speed Measurement System
87
Table 27: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
87
Table 28: Malfunction of the Speed Measurement System - Measured Speed too High
87
Table 29: Malfunction of the Speed Measurement System - Measured Speed too Low
87
Dismantling and Fitting
88
Introduction
88
Fig. 26: Swivel Lifting Eyes
90
Fig. 27: Starpoint Ring Nut VRM
90
Table 30: Swivel Lifting Eyes
90
Weights of Individual Parts
90
Fig. 28: Weights of Assemblies
91
Table 31: Weights of Assemblies
91
Fig. 29: Removing the Air Inlets
92
Removing the Air Inlets
92
Fig. 30: Removing the Gas Outlet Casing
93
Removing the Gas Outlet Casing
93
Removing the Gas Outlet Flange
93
Fig. 31: Dismantling the Gas Outlet Flange
94
Table 32: 3 Press-Off Screws
94
Fig. 32: Removing the Gas Outlet Flange
95
Table 33: 6 Press-Off Screws
95
Fig. 33: Removing the Compressor Casing
96
Removing the Compressor Casing
96
Fig. 34: Dismantling the Wall Insert
97
Fig. 35: Press off the Casing
98
Pressing off the Casing
98
Fig. 36: Oil Orifice
99
Fig. 37: Removing Cartridge Group 1
99
Removing the Cartridge Group
99
Fig. 38: Removing Cartridge Group 2
100
Fig. 39: Removing the Nozzle Ring
101
Removing the Nozzle Ring
101
Fig. 40: Installing the Cartridge Group on the Service Support
102
Installing the Cartridge Group on the Service Support
102
Fig. 41: Measuring Clearance a and B
103
Measuring Clearance a and B
103
Table 34: Permissible Clearances a and B
103
Fig. 42: Nozzle Ring Compression PD
104
Nozzle Ring Compression PD
104
Table 35: Nozzle Ring Compression PD
104
Fig. 43: Installing the Nozzle Ring
105
Installing the Nozzle Ring
105
Fig. 44: Measuring the End Position of the Nozzle Ring
106
Fig. 45: Lifting the Cartridge Group and Rotating It
106
Installing the Cartridge Group
106
Table 36: End Position of the Nozzle Ring, Control Dimension H
106
Fig. 46: Installing the Cartridge Group
107
Table 37: Tightening Torque (51007)
107
Fig. 47: Fitting the Wall Insert and the Diffuser
108
Fig. 48: Installing the Compressor Casing
108
Installing the Compressor Casing
108
Table 38: Tightening Torque (79041)
108
Table 39: Tightening Torque (72011)
109
Fig. 49: Measuring Clearances N and R
110
Measuring Radial Clearances N and R
110
Table 40: Permissible Clearances N and R
110
Fig. 50: Installing the Air Inlets
111
Installing the Air Inlets
111
Table 41: Tightening Torque (72020)
111
Fig. 51: Installing the Gas Outlet Flange
112
Fig. 52: Installing the Gas Outlet Casing
112
Installing the Gas Outlet Casing
112
Installing the Gas Outlet Flange
112
Table 42: Tightening Torque (51009)
112
Fig. 53: Tightening Torques
113
Table 43: Tightening Torques of the Screw Fittings
113
Table of Tightening Torques
113
Possible Emergency Repairs
114
Taking out of Operation at Short Notice
114
Installing the Replacement Cartridge Group
115
Installing the Replacement Turbocharger
115
Mothballing the Turbocharger
116
Taking the Engine out of Operation for up to 12 Months
116
Taking the Engine out of Operation for more than 12 Months
117
Disposing of Turbocharger Components
118
Ordering Spare Parts
119
Required Customer Spare Part Set (97070)
119
Spare Parts
119
Table 44: Customer Spare Part Set 97070
119
Fig. 54: Overview of Part Numbers
120
View of Turbocharger with Part Numbers
120
Table 45: Spare Parts List
121
Figures
122
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Operation Manual
124 pages
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ABB HT604133 Specifications
General
Brand
ABB
Model
HT604133
Category
Industrial Equipment
Language
English
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