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HT613191
ABB HT613191 User Manual
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Operation Manual / A130-M.. - A145-M..
1 Introduction / 1.7 Registered trademarks
© Copyright 2022 ABB. All rights reserved.
HZTL4031_EN
Rev.P
February 2022
1.7
Registered trademarks
The trademarks of outside companies are used in this document. These are marked with the
® symbol.
Page 12 / 149
13
15
Table of Contents
Operation Manual / A130-M - A145-M
3
Table of Contents
3
Operation Manual / A130-M
6
Introduction
6
Purpose of the Manual
6
Fig. 1: Serial Number (01) on the Rating Plate
6
Contact Information
7
Essential Information
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
Registered Trademarks
14
Safety
15
Introduction
15
CE Conformity
15
Definition of Mandatory Signs
16
Definition of Safety Instructions
16
Table 2: Personal Protective Equipment to be Worn at All Times
16
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
16
Intended Use
17
Deflagration on Gas Engines
18
Warning Plates on the Turbocharger
19
Fig. 6: Warning Plate Locations
19
Turbocharger Rating Plate
20
Fig. 7: Rating Plate
20
Fig. 8: Locations of the Rating Plates
21
Periodic Check of the Pressure Vessels
22
Lifting of Loads
23
Fig. 9: Attachment of Loads on the Crane Hook
23
Fig. 10: Attachment Angle
23
Prerequisites for Operation and Maintenance
24
Hazards During Operation and Maintenance
25
Safe Operation
27
Fig. 11
27
Safe Maintenance
28
Removing and Installing
32
Turbocharger Weight and Transportation
32
Fig. 12: Suspension of Complete Turbocharger Unit
32
Table 4: Weight of Complete Turbocharger Unit
32
Fig. 13: Turbine Cleaning Nozzle
33
Removing the Turbocharger
33
Fig. 14: Removing the Turbocharger
34
Fig. 15: Loosening the Clamping Nut
36
Fig. 16: Turbocharger Centre of Gravity
37
Installing the Turbocharger
38
Fig. 17: Inserting Gaskets into the Bracket
38
Fig. 18: Fitting Threaded Rods Onto the Bracket
39
Fig. 19: Requirements for Threaded Rods
39
Table 5: Requirements for Threaded Rods
39
Fig. 20: Placing the Turbocharger on the Bracket
40
Table 6: Tightening Torque for Standard Nuts
41
Fig. 21: Preparing the Clamping Nut for the Tightening Procedure
42
Fig. 22: Tightening Pressure Screws
43
Table 7: Torque-Controlled Tightening of the Pressure Screws
43
Fig. 23: Connecting the Speed Sensor
44
Fig. 24: Connecting the Compressor Cooling Air Intake
44
Fig. 25: Attaching the Support
45
Commissioning
46
Oil Supply
46
Fig. 26: Oil Orifice
46
Inspection Procedures
48
Commissioning after Taking out of Operation
50
Monitoring Operation
51
Oil Pressure, Oil Temperature
51
Table 8: Lubricating Oil Pressure at Oil Inlet before Turbocharger
51
Table 9: Lubricating Oil Temperature at the Inlet
52
Table 10: Lubricating Oil Temperature at the Outlet
52
Exhaust Gas Temperature before Turbine
53
Fig. 27: Layout and Overview of Speed Measurement System
54
Turbocharger Speed
54
Fig. 28: Replacing the Speed Sensor
56
Table 11: Tightening Torque (86505)
56
Operation and Service
57
Noise Emission
57
Fig. 29: Noise Insulation, Bellows
58
Service Work
59
Fig. 30: Replacing the Protective Grid
61
Expected Replacement Intervals
63
Table 12: Expected Replacement Intervals
63
Stopping the Engine
65
Periodic Maintenance Work
66
Foreword to Maintenance
66
Table 13: Maintenance Table
66
Cleaning the Compressor During Operation
67
Fig. 31: Carrying out Wet Cleaning of Compressor
69
Table 14: Parameters for Wet Cleaning of Compressor
69
Cleaning the Turbine During Operation
70
Table 15: Turbine Wet Cleaning, Recommended Operating State
72
Fig. 32: Carrying out Wet Cleaning of Turbine
73
Table 16: Wet Cleaning of Turbine, Parameters
73
Cleaning Components Mechanically
74
Fig. 33: Cleaning the Filter Silencer
75
Fig. 34: Compressor-End, Non-Rotating Parts
77
Fig. 35: Turbine End, Non-Rotating Parts
78
Fig. 36: Soaking the Turbine End
81
Table 17: Value Table for Soaking
81
Table 20: Malfunctions When Starting - Rubbing of Rotating Parts
84
Table 19: Malfunctions When Starting - Vibrations
84
Table 18: Malfunctions When Starting - Delayed Start-Up
84
Malfunctions When Starting
84
Eliminating Malfunctions
84
Malfunctions During Operation
85
Table 21: Malfunctions During Operation - Lubricating Oil Pressure too Low
85
Table 22: Malfunctions During Operation - Speed Reduces
85
Table 23: Malfunctions During Operation - Speed Increases
85
Table 24: Malfunctions During Operation - Exhaust Gas Temperature too High
86
Table 25: Malfunctions During Operation - Charge Air Pressure too Low
86
Table 26: Malfunctions During Operation - Charge Air Pressure too High
87
Table 27: Malfunctions During Operation - Engine Performance Losses
87
Turbocharger Is Surging
88
Table 28: Malfunction - Turbocharger Surging
88
Table 29: Malfunction - Sporadic Surge Blows
88
Table 31: Malfunctions When Stopping - Runout Time too Short
89
Table 30: Malfunctions When Stopping - Runout Noises
89
Malfunctions When Stopping
89
Speed Measurement System
90
Table 32: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
90
Table 33: Malfunction of the Speed Measurement System - Measured Speed too High
90
Table 34: Malfunction of the Speed Measurement System - Measured Speed too Low
90
Dismantling and Fitting
91
Introduction
91
Material Required
92
Fig. 37: Swivel Lifting Eye (Example)
92
Table 35: Swivel Lifting Eyes
92
Fig. 38: Starpoint Ring Nut VRM
93
Weights of Individual Parts
94
Fig. 39: Weights of Assemblies
94
Table 36: Weights of Assemblies
94
Fig. 40: Removing the Air Inlets
95
Removing the Air Inlets
95
Fig. 41: Removing the Insulation
96
Removing the Gas Outlet Casing
96
Fig. 42: Removing the Gas Outlet Casing
97
Removing the Gas Outlet Flange
97
A130 A135 A140 A145
98
Fig. 43: Dismantling the Gas Outlet Flange
98
Table 37: 3 Press-Off Screws
98
Fig. 44: Removing the Gas Outlet Flange
99
Table 38: 6 Press-Off Screws
99
Compressor Casing
100
Fig. 45: Removing the Compressor Casing
100
Removing the Compressor Casing
100
Fig. 46: Dismantling the Wall Insert
101
Wall Insert
101
Fig. 47: Press off the Casing
102
Pressing off the Casing
102
Cartridge Group
103
Fig. 48: Removing Insulation Sheets
103
Fig. 49: Oil Orifice
103
Removing the Cartridge Group
103
Fig. 50: Removing Cartridge Group 1
104
Fig. 51: Removing Cartridge Group 2
104
Fig. 52: Removing the Nozzle Ring
105
Removing the Nozzle Ring
105
Fig. 53: Installing the Cartridge Group on the Service Support
106
Installing the Cartridge Group on the Service Support
106
Fig. 54: Measuring Clearance a and B
107
Measuring Clearance a and B
107
Table 39: Permissible Clearances a and B
107
Fig. 55: Nozzle Ring Compression PD
108
Nozzle Ring Compression PD
108
Table 40: Nozzle Ring Compression PD
108
Fig. 56: Installing the Nozzle Ring
109
Installing the Nozzle Ring
109
Fig. 57: Lifting the Cartridge Group and Rotating It by 90
110
Installing the Cartridge Group
110
Fig. 58: Installing the Cartridge Group
111
Table 41: Tightening Torque (51007)
111
Fig. 59: Turbine Casing Insulation / Burst Protection
112
Installing the Compressor Casing
113
Table 42: Tightening Torque (79041)
113
Fig. 60: Installing the Compressor Casing
114
Table 43: Tightening Torque (72011)
114
Fig. 61: Measuring Clearances N and R
115
Measuring Radial Clearances N and R
115
Table 44: Permissible Clearances N and R
115
Fig. 62: Installing the Air Inlets
116
Installing the Air Inlets
116
Table 45: Tightening Torque (72020)
116
Fig. 63: Installing the Gas Outlet Flange
117
Gas Outlet Flange
117
Installing the Gas Outlet Flange
117
Fig. 64: Fitting the Insulation
118
Fitting the Insulation of the Turbine Casing
118
Fig. 65: Installing the Gas Outlet Casing
119
Installing the Gas Outlet Casing
119
Table 46: Tightening Torque (51009)
119
Fig. 66: Fitting the Insulation
120
Fig. 67: Tightening Torques
121
Table 47: Tightening Torques
121
Table of Tightening Torques
121
Fig. 68: Tightening Torques for Insulation
122
Table 48: Tightening Torques for Insulation
122
Possible Emergency Repairs
123
Taking out of Operation at Short Notice
123
Installing the Replacement Cartridge Group
124
Installing the Replacement Turbocharger
124
Fig. 69: Fitting the Cover Plate
125
Fitting the Cover Plate
125
Cover Plate Drawing
126
Fig. 70: Cover Plate Drawing
126
Table 49: Cover Plate Dimensions [MM]
126
Mothballing the Turbocharger
127
Taking the Engine out of Operation for up to 12 Months
127
Taking the Engine out of Operation for more than 12 Months
128
Material and Disposal
129
REACH and Rohs Compliance Declaration for Products
129
Disposing of Turbocharger Components
130
Ordering Spare Parts
131
Required Customer Spare Part Set (97070)
131
Spare Parts
131
Table 50: Customer Spare Part Set 97070
131
Spare Part - Illustrations
132
Table 51: Spare Parts - Cartridge, Oil Cooled
132
Table 52: Spare Parts - Cartridge, Water Cooled
133
Table 53: Spare Parts - Turbine Casing, 1 Inlet
135
Table 54: Spare Parts - Turbine Casing, 2 Inlets
137
Table 55: Spare Parts - Gas Outlet Casing, Axial
138
Table 56: Spare Parts - Gas Outlet Casing, Radial
139
Table 57: Spare Parts - Compressor Casing
140
Table 58: Spare Parts - Filter Silencer
141
Table 59: Spare Parts - Air Suction Branch Axial
142
Table 60: Spare Parts - Air Suction Branch Radial
143
Table 61: Spare Parts - Bearing Casing, Oil Cooled
144
Table 62: Spare Parts - Bearing Casing, Water Cooled
145
Table 63: Spare Parts - Rotor and Bearing Parts
146
Table 64: Customer Tool Set 90000
147
Tools
147
Figures
148
Tables
150
4
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ABB HT613191 Specifications
General
Brand
ABB
Model
HT613191
Category
Industrial Equipment
Language
English
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