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ABB HT604133 User Manual
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Operation Manual / A130-H.. - A140-H..
5 Monitoring operation / 5.3 Turbocharger speed
© Copyright 2021 ABB. All rights reserved.
HZTL4030_EN
Rev.G
July 2021
5.3.2
Layout and overview
Fig.24: Layout and overview of speed measurement system
86505
Speed sensor
42188
Screw plug
86515
Cable connector
42189
Gasket
86526
F/I converter
01
Plug with integrated voltage limiter
86528
Tachometer
*)
Installation variant for speed sensor
32109
Sealing disc with cams
Page 48 / 122
49
51
Table of Contents
Operation Manual / A130-H - A140-H
3
Table of Contents
3
Operation Manual / A130-H
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 of the Turbocharger
8
Fig. 3: Compressor Wheel Cooling
9
Symbols, Definitions
10
Table 1: Definition of Pictograms
11
Storage of New Turbochargers and Spare Parts
12
Fig. 4: Volatile Corrosion Inhibitor (VCI)
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
Periodic Check of the Pressure Vessels
17
Deflagration on Gas Engines
17
Fig. 6: Warning Plate Locations
18
Warning Plates on the Turbocharger
18
Turbocharger Rating Plate
19
Fig. 7: 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
Table 4: Weight of Complete Turbocharger Unit
30
Removing and Installing
30
Fig. 11: Transportation of the Turbocharger
30
Weight and Transportation of the Turbocharger
30
Removing the Turbocharger
31
Fig. 12: Removing the Turbocharger
31
Fig. 13: Loosening the Clamping Nut
33
Fig. 14: Putting down the Turbocharger
34
Installing the Turbocharger
35
Fig. 15: Inserting Gaskets into the Bracket
35
Fig. 16: Fitting Threaded Rods Onto the Bracket
36
Fig. 17: Requirements for Threaded Rods
36
Table 5: Requirements for Threaded Rods
36
Fig. 18: Placing the Turbocharger on the Bracket
37
Table 6: Tightening Torque for Standard Nuts
38
Fig. 19: Preparing the Clamping Nut for the Tightening Procedure
39
Fig. 20: Tightening Pressure Screws
40
Table 7: Torque-Controlled Tightening of the Pressure Screws
40
Fig. 21: Connecting the Compressor Cooling Air Intake
41
Fig. 22: Attaching the Support
41
Commissioning
42
Oil Supply
42
Fig. 23: Oil Orifice
43
Inspection Procedures
44
Commissioning after Taking out of Operation
46
Table 8: Lubricating Oil Pressure at Oil Inlet before Turbocharger
47
Oil Pressure, Oil Temperature
47
Monitoring Operation
47
Table 9: Lubricating Oil Temperature at the Inlet
48
Table 10: Lubricating Oil Temperature at the Outlet
48
Exhaust Gas Temperature before Turbine
49
Turbocharger Speed
49
Fig. 24: Layout and Overview of Speed Measurement System
50
Fig. 25: Replacing the Speed Sensor
52
Table 11: Tightening Torque (86505)
52
Operation and Service
53
Noise Emission
53
Fig. 26: Noise Insulation, Bellows
54
Service Work
55
Fig. 27: Replacing the Protective Grid
57
Expected Replacement Intervals
59
Table 12: Expected Replacement Intervals
60
Stopping the Engine
61
Periodic Maintenance Work
62
Foreword to Maintenance
62
Table 13: Maintenance Table
62
Cleaning Components Mechanically
63
Fig. 28: Cleaning the Filter Silencer
64
Fig. 29: Compressor-End, Non-Rotating Parts
66
Fig. 30: Turbine End, Non-Rotating Parts
67
Fig. 31: Soaking the Turbine End
70
Table 14: Value Table for Soaking
70
Table 16: Malfunctions When Starting - Vibrations
73
Table 17: Malfunctions When Starting - Rubbing of Rotating Parts
73
Eliminating Malfunctions
73
Table 15: Malfunctions When Starting - Delayed Start-Up
73
Malfunctions When Starting
73
Malfunctions During Operation
74
Table 18: Malfunctions During Operation - Lubricating Oil Pressure too Low
74
Table 19: Malfunctions During Operation - Speed Reduces
74
Table 20: Malfunctions During Operation - Speed Increases
74
Table 21: Malfunctions During Operation - Exhaust Gas Temperature too High
75
Table 22: Malfunctions During Operation - Charge Air Pressure too Low
75
Table 23: Malfunctions During Operation - Charge Air Pressure too High
76
Table 24: Malfunctions During Operation - Engine Performance Losses
76
Table 26: Malfunction - Sporadic Surge Blows
77
Table 25: Malfunction - Turbocharger Pumping
77
Turbocharger Is Surging
77
Malfunctions When Stopping
78
Table 27: Malfunctions When Stopping - Runout Noises
78
Table 28: Malfunctions When Stopping - Runout Time too Short
78
Speed Measurement System
79
Table 29: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
79
Table 30: Malfunction of the Speed Measurement System - Measured Speed too High
79
Table 31: Malfunction of the Speed Measurement System - Measured Speed too Low
79
Dismantling and Fitting
80
Introduction
80
Table 32: Swivel Lifting Eyes
82
Fig. 33: Starpoint Ring Nut VRM
82
Fig. 32: Swivel Lifting Eyes
82
Weights of Individual Parts
82
Fig. 34: Weights of Assemblies/Table 33: Weights of Assemblies
83
Fig. 34: Weights of Assemblies
83
Table 33: Weights of Assemblies
83
Fig. 35: Removing the Air Inlets
84
Removing the Air Inlets
84
Fig. 36: Removing the Gas Outlet Casing
85
Removing the Gas Outlet Casing
85
Removing the Gas Outlet Flange
85
A130 A135 A140
86
Fig. 37: Dismantling the Gas Outlet Flange
86
Table 34: 3 Press-Off Screws
86
Fig. 38: Removing the Gas Outlet Flange
87
Table 35: 6 Press-Off Screws
87
Compressor Casing
88
Fig. 39: Removing the Compressor Casing
88
Removing the Compressor Casing
88
Fig. 40: Dismantling the Wall Insert
89
Wall Insert
89
Fig. 41: Press off the Casing
90
Pressing off the Casing
90
Fig. 42: Oil Orifice
91
Fig. 43: Removing Cartridge Group 1
91
Removing the Cartridge Group
91
Fig. 44: Removing Cartridge Group 2
92
Fig. 45: Removing the Nozzle Ring
93
Removing the Nozzle Ring
93
Fig. 46: Installing the Cartridge Group on the Service Support
94
Installing the Cartridge Group on the Service Support
94
Fig. 47: Measuring Clearance a and B
95
Measuring Clearance a and B
95
Table 36: Permissible Clearances a and B
95
Fig. 48: Nozzle Ring Compression PD
96
Nozzle Ring Compression PD
96
Table 37: Nozzle Ring Compression PD
96
Fig. 49: Installing the Nozzle Ring
97
Installing the Nozzle Ring
97
Fig. 50: Measuring the End Position of the Nozzle Ring
98
Fig. 51: Lifting the Cartridge Group and Rotating It by 90
98
Installing the Cartridge Group
98
Table 38: End Position of the Nozzle Ring, Control Dimension H
98
Fig. 52: Installing the Cartridge Group
99
Table 39: Tightening Torque (51007)
99
Fig. 53: Fitting the Wall Insert and the Diffuser
100
Installing the Compressor Casing
100
Table 40: Tightening Torque (79041)
100
Fig. 54: Installing the Compressor Casing
101
Table 41: Tightening Torque (72011)
101
Fig. 55: Measuring Clearances N and R
102
Measuring Radial Clearances N and R
102
Table 42: Permissible Clearances N and R
102
Fig. 56: Installing the Air Inlets
103
Installing the Air Inlets
103
Table 43: Tightening Torque (72020)
103
Fig. 57: Installing the Gas Outlet Flange
104
Fig. 58: Installing the Gas Outlet Casing
104
Installing the Gas Outlet Casing
104
Installing the Gas Outlet Flange
104
Table 44: Tightening Torque (51009)
104
Fig. 59: Tightening Torques
105
Table 45: Tightening Torques of the Screw Fittings
105
Table of Tightening Torques
105
Possible Emergency Repairs
106
Taking out of Operation at Short Notice
106
Installing the Replacement Cartridge Group
107
Installing the Replacement Turbocharger
107
Mothballing the Turbocharger
108
Taking the Engine out of Operation for up to 12 Months
108
Taking the Engine out of Operation for more than 12 Months
109
Material and Disposal
110
REACH and Rohs Compliance Declaration for Products
110
Disposing of Turbocharger Components
111
Ordering Spare Parts
112
Required Customer Spare Part Set (97070)
112
Spare Parts
112
Table 46: Customer Spare Part Set 97070
112
Spare Part - Illustrations
113
Table 47
113
Gas Outlet Flange
114
Nozzle Ring 2 2
114
Turbine Casing * 45 65
114
Gas Outlet Casing
115
Table 48
115
Table 49
115
Table 50
116
Table 51
117
Fig. 60: SPI Air Suction Branch Radial
118
Table 52: Spare Parts - Air Suction Branch Radial
118
Table 53
119
Table 54
120
Tools
121
Figures
122
Tables
123
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Original 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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