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HT604449
ABB HT604449 Instruction Manual
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Operating limits and replacement intervals
The recommended replacement intervals and the corresponding operating limits in
chapter 3
are jointly defined
with the enginebuilder. This information is specific to the product.
Non-observance of the recommended replacement intervals and the operating limits increases the risk of unpre-
dictable component failures.
1
3
Table of Contents
Introduction
3
Table of Contents
3
Purpose of the Manual
4
Symbols, Definitions
5
Storage of New Turbochargers and Spare Parts
7
Contact Information
9
Safety
11
CE Conformity
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
Introduction
32
Essential Information
34
Introduction
34
Registered Trademarks
34
Related Documents
35
Table 1: Related Documents
35
Fig. 1: Layout and Function of the Turbocharger
36
Layout and Function of the Turbocharger
36
Fig. 2: Compressor Wheel Cooling
37
Fig. 3: Warning Plate Locations
38
Warning Plates on the Turbocharger
38
Fig. 4: Locations of the Rating Plates
39
Locations of the Rating Plates
39
Fig. 5: Suspension of Complete Turbocharger Unit
40
Removing and Installing
40
Table 2: Weight of Complete Turbocharger Unit
40
Turbocharger Weight and Transportation
40
Fig. 6: Turbine Cleaning Nozzle
41
Fig. 7: Removing the Turbocharger
41
Removing the Turbocharger
41
Fig. 8: Loosening the Clamping Nut
42
Fig. 9: Turbocharger Centre of Gravity
43
Fig. 10: Inserting the Gasket
44
Installing the Turbocharger
44
Fig. 11: Fitting the Turbocharger 1
45
Fig. 12: Fitting the Turbocharger 2
46
Table 3: Fitting the Turbocharger, Value X, L
46
Fig. 13: Preparing the Clamping Nut for the Tightening Procedure
47
Fig. 14: Tightening Pressure Screws
48
Table 4: Torque-Controlled Tightening of the Pressure Screws
48
Fig. 15: Connecting the Speed Sensor
49
Fig. 16: Connecting the Compressor Cooling Air Intake
49
Fig. 17: Attaching the Support
49
Commissioning
50
Oil Supply
50
Fig. 18: Oil Orifice
51
Inspection Procedures
52
Commissioning after Taking out of Operation
54
Monitoring Operation
55
Oil Pressure, Oil Temperature
55
Table 5: Lubricating Oil Pressure at Oil Inlet before Turbocharger
55
Table 6: Lubricating Oil Temperature at the Inlet
56
Table 7: Maximum Lubricating Oil Temperature at the Outlet
56
Exhaust Gas Temperature before Turbine
57
Fig. 19: Layout and Overview of Speed Measurement System
58
Turbocharger Speed
58
Fig. 20: Replacing the Speed Sensor
60
Table 8: Tightening Torque (86505)
60
Noise Emission
61
Operation and Service
61
Fig. 21: Noise Insulation, Bellows
62
Service Work
63
Expected Replacement Intervals
66
Table 9: Expected Replacement Intervals
66
Stopping the Engine
68
Foreword to Maintenance
69
Periodic Maintenance Work
69
Table 10: Maintenance Table
69
Cleaning the Compressor During Operation
70
Fig. 22: Carrying out Wet Cleaning of Compressor
72
Table 11: Parameters for Wet Cleaning of Compressor
72
Cleaning the Turbine During Operation
73
Fig. 23: Turbine Cleaning Devices
75
Table 12: Turbine Wet Cleaning, Recommended Operating State
75
Fig. 24: Carrying out Wet Cleaning of Turbines
76
Table 13: Wet Cleaning of Turbines, Parameters for 1-Nozzle Cleaning
76
Cleaning Components Mechanically
77
Table 14: Wet Cleaning of Turbines, Parameters for 6-Nozzle Cleaning
77
Fig. 25: Cleaning the Filter Silencer
78
Fig. 26: Compressor-End, Non-Rotating Parts
80
Fig. 27: Turbine End, Non-Rotating Parts
82
Fig. 28: Soaking the Turbine End
84
Table 15: Value Table for Soaking
84
Changing the Absorption Element
87
Fig. 29: Disassembling the Absorption Element
87
Fig. 30: Installing the Absorption Element
88
Table 16: Tightening Torque (81152 / 81154)
88
Eliminating Malfunctions
89
Malfunctions When Starting
89
Table 17: Malfunctions When Starting - Delayed Start-Up
89
Table 18: Malfunctions When Starting - Vibrations
89
Table 19: Malfunctions When Starting - Rubbing of Rotating Parts
89
Malfunctions During Operation
90
Table 20: Malfunctions During Operation - Lubricating Oil Pressure too Low
90
Table 21: Malfunctions During Operation - Speed Reduces
90
Table 22: Malfunctions During Operation - Speed Increases
90
Table 23: Malfunctions During Operation - Exhaust Gas Temperature too High
91
Table 24: Malfunctions During Operation - Charge Air Pressure too Low
91
Table 25: Malfunctions During Operation - Charge Air Pressure too High
92
Table 26: Malfunctions During Operation - Engine Performance Losses
92
Table 27: Malfunction - Turbocharger Pumping
93
Table 28: Malfunction - Sporadic Surge Blows
93
Turbocharger Is Surging
93
Malfunctions When Stopping
94
Table 29: Malfunctions When Stopping - Runout Noises
94
Table 30: Malfunctions When Stopping - Runout Time too Short
94
Speed Measurement System
95
Table 31: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
95
Table 32: Malfunction of the Speed Measurement System - Measured Speed too High
95
Table 33: Malfunction of the Speed Measurement System - Measured Speed too Low
95
Dismantling and Fitting, General
96
Introduction
96
Fig. 31: Swivel Lifting Eyes
97
Material Required
97
Table 34: Swivel Lifting Eyes
97
Fig. 32: Press-Off Screws
98
Fig. 33: Dismantling Screw
98
Table 35: Press-Off Screws
98
Table 36: Dismantling Screw
98
Disassembly and Assembly Concepts
100
Fig. 34: Removing the Cartridge Group with Compressor and Turbine Casing
100
Fig. 35: Cartridge Concept
101
Fig. 36: Optional Spanner Holder
102
Fig. 37: Weights of Assemblies
103
Table 37: Weights of Assemblies
103
Weights of Individual Parts
103
Fig. 38: Overview of Tightening Torques
104
Table of Tightening Torques
104
Table 38: Tightening Torques
105
Fig. 39: Tightening Torques for Insulation
106
Table 39: Tightening Torques for Insulation
106
Dismantling and Fitting with Removed Air Inlet and Gas Outlet
107
Fig. 40: Removing the Air Inlets
107
Removing Air Inlets
107
Fig. 41: Removing the Uncoupled Filter Silencer
108
Fig. 42: Remove Gas Outlet Casing Without Support
109
Removing the Gas Outlet Casing
109
Fig. 43: Removing Gas Outlet Casing with Support 1
110
Fig. 44: Removing Gas Outlet Casing with Support 1
111
Removing the Gas Outlet Flange
112
Fig. 45: Dismantling the Gas Outlet Flange
113
Table 40: 3 Press-Off Screws
113
Fig. 46: Removing the Gas Outlet Flange
114
Table 41: 6 Press-Off Screws
114
Fig. 47: Turbine Cleaning Nozzle
115
Fig. 48: Remove Insulation
115
Removing the Cartridge Group with Compressor and Turbine Casing
115
Fig. 49: Removing the Cartridge Group with Compressor and Turbine Casing
116
Fig. 50: Set down the Cartridge Group with the Compressor and Turbine Casing
116
Fig. 51: Removing the Compressor Casing
117
Removing the Compressor Casing
117
Fig. 52: Dismantling the Diffuser and the Wall Insert
118
Fig. 53: Removing Cartridge Group 1
119
Removing the Cartridge Group
119
Table 42: Tightening Torque (90012-01)
119
Fig. 54: Removing Cartridge Group 2
120
Fig. 55: Removing Cartridge Group 3
121
Fig. 56: Installing the Cartridge Group on the Service Support
122
Installing the Cartridge Group on the Service Support
122
Fig. 57: Removing the Nozzle Ring
123
Removing the Nozzle Ring
123
Fig. 58: Measuring Clearance a and B
124
Measuring Clearance a and B
124
Table 43: Permissible Clearances a and B
124
Fig. 59: Nozzle Ring Compression PD
125
Nozzle Ring Compression PD
125
Table 44: Nozzle Ring Compression PD
125
Fig. 60: Installing the Nozzle Ring
126
Installing Nozzle Ring
126
Fig. 61: Lifting the Cartridge Group and Rotating It by 90
127
Installing the Cartridge Group
127
Fig. 62: Turning the Cartridge Group
128
Table 45: Tightening Torque (90012-01)
128
Fig. 63: Installing the Cartridge Group
129
Table 46: Tightening Torque (51007)
129
Fig. 64: Fitting the Wall Insert and the Diffuser
130
Installing the Compressor Casing
130
Table 47: Tightening Torque (79041)
130
Fig. 65: Installing the Compressor Casing
131
Table 48: Tightening Torque (72011)
131
Fig. 66: Turning the Cartridge Group with Compressor and Turbine Casing
132
Turning the Cartridge Group with Compressor and Turbine Casing
132
Fig. 67: Installing the Gas Outlet Flange
133
Installing the Gas Outlet Flange
133
Fig. 68: Measuring Clearances N and R
134
Radial Clearances N and R
134
Table 49: Permissible Clearances N and R
134
Fig. 69: Fitting the Insulation
135
Fitting the Insulation
135
Fig. 70: Installing the Cartridge Group with Compressor and Turbine Casing
136
Fig. 71: Installing the Cartridge Group with Compressor and Turbine Casing
136
Installing the Cartridge Group with Compressor and Turbine Casing
136
Fig. 72: Fitting Gas Outlet Casing Without Support
137
Installing the Gas Outlet Casing
137
Table 50: Tightening Torque (51009)
137
Fig. 73: Installing Gas Outlet Casing with Support 1
138
Table 51: Tightening Torque (51009)
138
Fig. 74: Installing Gas Outlet Casing with Support 2
139
Fig. 75: Installing the Air Inlets
140
Installing Air Inlets
140
Table 52: Tightening Torque (72051)
140
Fig. 76: Installing the Uncoupled Filter Silencer
141
Table 53: Tightening Torque (72054)
141
Dismantling and Fitting, Cartridge Concept
142
Fig. 77: Removing the Air Inlets
142
Removing Air Inlets
142
Fig. 78: Removing the Uncoupled Filter Silencer
143
Fig. 79: Removing the Compressor Casing
144
Removing the Compressor Casing
144
Fig. 80: Pressing off Compressor Casing
145
Fig. 81: Remove the Diffuser
145
Fig. 82: Dismantling the Diffuser and the Wall Insert
146
Fig. 83: Removing Insulation Sheets
147
Removing the Cartridge Group
147
Fig. 84: Removing Cartridge Group 1
148
Table 54: Threaded Rod, Value X
148
Fig. 85: Removing Cartridge Group 2
149
Fig. 86: Removing Cartridge Group 2
150
Fig. 87: S_05180
151
Removing the Nozzle Ring
151
Fig. 88: Measuring Clearance a and B
152
Measuring Clearance a and B
152
Table 55: Permissible Clearances a and B
152
Fig. 89: Nozzle Ring Compression PD
153
Nozzle Ring Compression PD
153
Table 56: Nozzle Ring Compression PD
153
Fig. 90: Installing the Nozzle Ring
154
Installing Nozzle Ring
154
Fig. 91: Installing the Cartridge Group 1
155
Installing the Cartridge Group
155
Fig. 92: Installing the Cartridge Group 2
156
Table 57: Threaded Rod, Value X and L
156
Table 58: Tightening Torque (51007)
156
Fig. 93: Fitting the Wall Insert and the Diffuser
157
Installing the Compressor Casing
157
Table 59: Tightening Torque (79041)
157
Fig. 94: Installing the Compressor Casing
158
Table 60: Tightening Torque (72011)
158
Fig. 95: Measuring Clearances N and R
159
Radial Clearances N and R
159
Table 61: Permissible Clearances N and R
159
Fig. 96: Fitting the Insulation
160
Fitting the Insulation
160
Fig. 97: Installing the Air Inlets
161
Installing Air Inlets
161
Table 62: Tightening Torque (72051)
161
Fig. 98: Installing the Uncoupled Filter Silencer
162
Table 63: Tightening Torque (72054)
162
Dismantling and Fitting, Special Tools for Fastening Strips
163
Fig. 100: Customer Tool
164
Fig. 99: Customer Tool
164
Table 64: Customer Tool
164
Table 65: Customer Tool
164
Application, Special Tools
165
Fig. 101: Positioning the Collection Tub
165
Fig. 102: Removing the Fastening Strips
165
Fig. 103: Fitting the Upper Fastening Strips
167
Fig. 104: Fitting the Bottom Fastening Strip
167
Table 66: Tightening Torque (51007)
167
Fig. 105: Fitting the Bottom Fastening Strip
168
Table 67: Tightening Torque (51007) with Spanner Holder
168
Fig. 106: Fitting the Cartridge Group
169
Table 68: Tightening Torque (51007)
169
Fig. 107: Positioning the Fastening Strip
170
Fig. 108: Clamping Piece
171
Fig. 109: Attach Nut
172
Table 69: Tightening Torque (51007) with Spanner Holder
172
Disassembly
173
Fig. 110: Initial Situation
173
Fig. 111: Disassembly of the Elbows
173
Removing and Installing 6-Nozzle Turbine Cleaning Component (Optional)
173
Fig. 112: Disassembly of the Elbows
174
Fig. 113: Pipe Disassembly
174
Fig. 114: Disassembly of the Connecting Pieces
175
Fig. 115: Disassembly of the Cleaning Nozzle
175
Table 70: Dismantling Screw
175
Assembly
176
Fig. 116: Assembly of the Cleaning Nozzle
176
Fig. 117: Assembly of the Connecting Pieces
176
Table 71: Dismantling Screw
176
Fig. 118: Pipe Assembly
177
Fig. 119: Elbow 1 Assembly
177
Fig. 120: Elbow 2 Assembly
178
Table 72: Tightening Torque (51314 / 51316)
178
Fig. 121: Fit the Cleaning Nozzles
179
Fitting the Cleaning Nozzles with Multi-Inlet Turbine Casings
179
Possible Emergency Repairs
180
Taking out of Operation at Short Notice
180
Installing the Replacement Cartridge Group
181
Installing the Replacement Turbocharger
181
Fig. 122: Fitting the Cover Plate
182
Fitting the Cover Plate
182
Cover Plate Drawing
183
Fig. 123: Cover Plate Drawing
183
Table 73: Cover Plate Dimensions [MM]
183
Fig. 124: Dimensions for Cover Plate
184
Table 74: Cover Plate Dimensions [MM]
184
Mothballing the Turbocharger
185
Taking the Engine out of Operation for up to 12 Months
185
Taking the Engine out of Operation for more than 12 Months
186
Disposing of Turbocharger Components
187
Ordering Spare Parts
188
Required Customer Spare Part Set (97070)
188
Spare Parts
188
Table 75: Customer Spare Part Set 97070
188
Fig. 125: Overview of Part Numbers
190
View of Turbocharger with Part Numbers
190
Table 76: Spare Parts List
191
Fig. 126: Overview of Part Numbers
192
Table 77: Spare Parts List
192
View of Turbine Cleaning Device
192
Fig. 127: Overview of Part Numbers
193
Table 78: Spare Parts List
193
Fig. 128: Overview of Part Numbers
194
Table 79: Spare Parts List
194
View of Uncoupled Filter Silencer A155
194
Fig. 129: Special Tool
195
Table 80: Customer Tool Set 90000
195
Table 81: Special Tool (90160)
195
Tools
195
Fig. 130: Special Tool
196
Table 82: Special Tool (90160)
196
Figures
197
Tables
200
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ABB HT604449 Specifications
General
Brand
ABB
Model
HT604449
Category
Industrial Equipment
Language
English
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