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Operation Manual / TPS44-H.. - TPS52-H..
5 Monitoring operation / 5.3 Turbocharger speed
© Copyright 2021 ABB. All rights reserved.
HZTL4037_EN
Rev.F
May 2021
5.3.2
Layout and overview
Fig.16: Layout and overview of the 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
*)
Alternative mounting position for speed
sensor
32109
Sealing disc
Page 42 / 111
43
45
Table of Contents
Operation Manual / Tps44-H - Tps52-H
3
Table of Contents
3
Fig. 1: Serial Number (01) on the Rating Plate
6
Operation Manual / TPS44-H
6
Purpose of the Manual
6
Introduction
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
Symbols, Definitions
9
Table 1: Definition of Pictograms
11
Fig. 3: Volatile Corrosion Inhibitor (VCI)
12
Storage of New Turbochargers and Spare Parts
12
Fig. 4: 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
Warning Plates on the Turbocharger
18
Fig. 5: Warning Plate Locations
18
Turbocharger Rating Plate
19
Fig. 6: Rating Plate
19
Fig. 7: Position of the Rating Plate
20
Lifting of Loads
21
Fig. 8: Attachment of Loads on the Crane Hook
21
Fig. 9: Attachment Angle
21
Prerequisites for Operation and Maintenance
22
Hazards During Operation and Maintenance
23
Safe Operation
25
Safe Maintenance
26
Removing and Installing
30
Turbocharger Weight and Transportation
30
Fig. 10: Swivel Lifting Eyes
30
Table 4: Gesamtgewicht
30
Table 5: Swivel Lifting Eyes to be Used
30
Removing the Turbocharger
31
Fig. 11: Removing the Turbocharger
32
Installing the Turbocharger
33
Fig. 12: Inserting Gaskets into the Bracket
33
Table 6: Requirements for Threaded Rods
34
Fig. 14: Requirements for Threaded Rods
34
Fig. 13: Inserting Threaded Rods into the Bracket
34
Fig. 15: Placing the Turbocharger on the Bracket
35
Table 7: Tightening Torque for Standard Nuts
35
Commissioning
36
Oil Supply
36
Inspection Procedures
37
Commissioning after Taking out of Operation
39
Monitoring Operation
40
Oil Pressure, Oil Temperature
40
Table 8: Lubricating Oil Pressure at Oil Inlet before Turbocharger
40
Table 9: Lubricating Oil Temperature at the Inlet
42
Table 10: Lubricating Oil Temperature at the Outlet
42
Exhaust Gas Temperature before Turbine
43
Turbocharger Speed
43
Fig. 16: Layout and Overview of the Speed Measurement System
44
Fig. 17: Fitting the Speed Sensor
46
Table 11: Tightening Torque (86505)
46
Operation and Service
47
Noise Emission
47
Fig. 18: Noise Insulation, Bellows
48
Service Work
49
Expected Replacement Intervals
52
Table 12: Expected Replacement Intervals
53
Stopping the Engine
54
Periodic Maintenance Work
55
Foreword to Maintenance
55
Cleaning Components Mechanically
55
Table 13: Maintenance Table
55
Fig. 19: Cleaning the Filter Silencer
56
Fig. 20: Cleaning the Compressor Casing, Diffuser Mechanically
58
Fig. 21: Cleaning the Nozzle Ring, Turbine Casing Mechanically
59
Fig. 22: Soaking Contamination of the Turbine
61
Table 14: Dimensions of the Cleaning Container
61
Table 17: Malfunctions When Starting - Rotating Parts Rubbing
65
Table 16: Malfunctions When Starting - Vibrations
65
Table 15: Malfunctions When Starting - Delayed Start-Up
65
Malfunctions When Starting
65
Eliminating Malfunctions
65
Malfunctions During Operation
66
Table 18: Malfunctions During Operation - Lubricating Oil Pressure too Low
66
Table 19: Malfunctions During Operation - Speed Reduces
66
Table 20: Malfunctions During Operation - Speed Increases
66
Table 21: Malfunctions During Operation - Exhaust Gas Temperature too High
67
Table 22: Malfunctions During Operation - Charge Air Pressure too Low
67
Table 23: Malfunctions During Operation - Charge Air Pressure too High
68
Table 24: Malfunctions During Operation - Engine Performance Losses
68
Table 26: Malfunction - Sporadic Surge Blows
69
Turbocharger Is Surging
69
Table 25: Malfunction - Turbocharger Pumping
69
Malfunctions When Stopping
70
Table 27: Malfunctions When Stopping - Runout Noises
70
Table 28: Malfunctions When Stopping - Runout Time too Short
70
Speed Measurement System
71
Table 29: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
71
Table 30: Malfunction of the Speed Measurement System - Measured Speed too High
71
Table 31: Malfunction of the Speed Measurement System - Measured Speed too Low
71
Dismantling and Fitting
72
Introduction
72
Table 32: Swivel Lifting Eyes to be Used
73
Fig. 23: Swivel Lifting Eyes
73
Material Required
73
Fig. 24: Ring Nuts
74
Table 33: Ring Nuts to be Used (VRM)
74
Weights of Individual Parts
75
Fig. 25: Overview of Assemblies
75
Table 34: Weights of the Assemblies [Kg]
75
Removing the Gas Outlet Casing
76
Fig. 26: Removing the Gas Outlet Casing
76
Removing Air Inlets
77
Fig. 27: Removing Air Inlets
77
Fig. 29: Removing the Compressor Casing (2/2)
78
Fig. 28: Removing the Compressor Casing (1/2)
78
Removing the Compressor Casing
78
Removing the Cartridge Group
79
Fig. 30
79
Fig. 31: Do Not Loosen Screw Plugs
79
Fig. 32: Removing the Cartridge Group (1)
80
Fig. 33: Removing Cartridge Group 2
80
Fig. 34: Rotating the Cartridge Group and Fitting the Service Support
81
Removing Nozzle Ring
82
Fig. 35: Removing the Nozzle Ring
82
Table 35: Permissible Clearances a and B
83
Fig. 36: Measuring Clearance a and B
83
Measuring Clearance a and B
83
Nozzle Ring Compression PD
84
Fig. 37: Measuring Nozzle Ring Compression
84
Table 36: Nozzle Ring Compression PD
84
Fitting the Diffuser
85
Fig. 38: Fitting the Diffuser
85
Table 37: Tightening Torque (72041)
85
Installing the Cartridge Group
86
Fig. 39: Lifting the Cartridge Group and Rotating It
86
Fig. 40: Fitting the Cartridge Group
87
Table 38: Tightening Torque (72011)
87
Installing the Nozzle Ring
88
Fig. 41: Installing the Nozzle Ring
88
Fitting the Turbine Casing
89
Fig. 42: Fitting the Turbine Casing
89
Table 39: Tightening Torque (51007)
89
Turning the Turbocharger
90
Fig. 43: Rotating the Turbocharger
90
Measuring Radial Clearances N and R
91
Fig. 44: Measuring Clearances N and R
91
Table 40: Permissible Clearances N and R
91
Table 41: Tightening Torque (51008)
92
Fig. 45: Fitting the Gas Outlet Casing
92
Installing the Gas Outlet Casing
92
Installing Air Inlets
93
Fig. 46: Installing the Air Inlets
93
Table 42: Tightening Torque (72020)
93
Table of Tightening Torques
94
Fig. 47: Overview of Tightening Torques
94
Table 43: Overview of Tightening Torques
94
Taking out of Operation at Short Notice
95
Possible Emergency Repairs
95
Mothballing the Turbocharger
96
Taking the Engine out of Operation for up to 12 Months
96
Taking the Engine out of Operation for more than 12 Months
97
Material and Disposal
98
REACH and Rohs Compliance Declaration for Products
98
Disposing of Turbocharger Components
99
Spare Parts
100
Ordering Spare Parts
100
Required Customer Spare Part Set (97070)
100
Table 44: Customer Spare Part Set (97070)
100
Spare Part - Illustrations
101
Table 45: Spare Parts - Cartridge
101
Table 46: Spare Parts - Bearing Casing
102
Table 47: Spare Parts - Rotor and Bearing Parts
103
Table 48: Spare Parts - Turbine Casing
104
Table 49: Spare Parts - Compressor Casing
105
Table 50: Spare Parts - Filter Silencer
106
Table 51: Spare Parts - Air Suction Branch Radial
107
Table 52: Spare Parts - Air Suction Brach Axial
108
Table 53: Spare Parts - Gas Outlet Casing
109
Table 54: Spare Parts - Speed Measurement System
110
Tools
111
Table 55: TPS-H Tool
111
Figures
112
Tables
113
4
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ABB HT606422 Specifications
General
Brand
ABB
Model
HT606422
Category
Industrial Equipment
Language
English
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