ABB HT845527 - Page 10

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Table of Contents3
Introduction4
Purpose of the Manual4
Symbols, Definitions5
Storage of New Turbochargers and Spare Parts7
Contact Information9
Safety12
Introduction12
CE Conformity12
Definition of Mandatory Signs13
Definition of Safety Instructions13
Intended Use14
Deflagration on Gas Engines15
Warning Plates on the Turbocharger16
Turbocharger Rating Plate17
Periodic Check of the Pressure Vessels18
Lifting of Loads19
Prerequisites for Operation and Maintenance20
Hazards During Operation and Maintenance21
Safe Operation23
Safe Maintenance25
Introduction33
Essential Information33
Registered Trademarks33
Related Documents33
Table 1: Related Documents33
Layout and Function of the Turbocharger34
Fig. 1: Layout and Function of the Turbocharger34
Fig. 2: Compressor Wheel Cooling35
Warning Plates on the Turbocharger36
Fig. 3: Warning Plate Locations36
Locations of the Rating Plates37
Fig. 4: Locations of the Rating Plates37
Removing and Installing38
Weight and Transportation of the Turbocharger38
Fig. 5: Transportation of the Turbocharger38
Table 2: Weight of Complete Turbocharger Unit38
Removing the Turbocharger39
Fig. 6: Removing the Turbocharger39
Fig. 7: Loosening the Clamping Nut41
Fig. 8: Putting down the Turbocharger42
Installing the Turbocharger43
Fig. 9: Inserting Gaskets into the Bracket43
Fig. 10: Fitting Threaded Rods Onto the Bracket44
Fig. 11: Requirements for Threaded Rods44
Table 3: Requirements for Threaded Rods44
Fig. 12: Placing the Turbocharger on the Bracket45
Table 4: Tightening Torque for Standard Nuts46
Fig. 13: Preparing the Clamping Nut for the Tightening Procedure47
Fig. 14: Tightening Pressure Screws48
Table 5: Torque-Controlled Tightening of the Pressure Screws48
Fig. 15: Connecting the Compressor Cooling Air Intake49
Fig. 16: Attaching the Support49
Commissioning50
Oil Supply50
Fig. 17: Oil Orifice51
Inspection Procedures52
Commissioning after Taking out of Operation54
Monitoring Operation55
Oil Pressure, Oil Temperature55
Table 6: Lubricating Oil Pressure at Oil Inlet before Turbocharger55
Table 7: Lubricating Oil Temperature at the Inlet56
Table 8: Lubricating Oil Temperature at the Outlet56
Exhaust Gas Temperature before Turbine57
Turbocharger Speed58
Fig. 18: Layout and Overview of Speed Measurement System58
Fig. 19: Replacing the Speed Sensor60
Table 9: Tightening Torque (86505)60
Operation and Service61
Noise Emission61
Fig. 20: Noise Insulation, Bellows62
Service Work63
Fig. 21: Replacing the Protective Grid65
Expected Replacement Intervals67
Table 10: Expected Replacement Intervals68
Stopping the Engine69
Periodic Maintenance Work70
Foreword to Maintenance70
Table 11: Maintenance Table70
Cleaning Components Mechanically71
Fig. 22: Cleaning the Filter Silencer72
Fig. 23: Compressor-End, Non-Rotating Parts74
Fig. 24: Turbine End, Non-Rotating Parts75
Fig. 25: Soaking the Turbine End78
Table 12: Value Table for Soaking78
Eliminating Malfunctions81
Malfunctions When Starting81
Table 13: Malfunctions When Starting - Delayed Start-Up81
Table 14: Malfunctions When Starting - Vibrations81
Table 15: Malfunctions When Starting - Rubbing of Rotating Parts81
Malfunctions During Operation82
Table 16: Malfunctions During Operation - Lubricating Oil Pressure too Low82
Table 17: Malfunctions During Operation - Speed Reduces82
Table 18: Malfunctions During Operation - Speed Increases82
Table 19: Malfunctions During Operation - Exhaust Gas Temperature too High83
Table 20: Malfunctions During Operation - Charge Air Pressure too Low83
Table 21: Malfunctions During Operation - Charge Air Pressure too High84
Table 22: Malfunctions During Operation - Engine Performance Losses84
Turbocharger Is Surging85
Table 23: Malfunction - Turbocharger Pumping85
Table 24: Malfunction - Sporadic Surge Blows85
Malfunctions When Stopping86
Table 25: Malfunctions When Stopping - Runout Noises86
Table 26: Malfunctions When Stopping - Runout Time too Short86
Speed Measurement System87
Table 27: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude87
Table 28: Malfunction of the Speed Measurement System - Measured Speed too High87
Table 29: Malfunction of the Speed Measurement System - Measured Speed too Low87
Dismantling and Fitting88
Introduction88
Weights of Individual Parts90
Fig. 26: Swivel Lifting Eyes90
Fig. 27: Starpoint Ring Nut VRM90
Table 30: Swivel Lifting Eyes90
Fig. 28: Weights of Assemblies91
Table 31: Weights of Assemblies91
Removing the Air Inlets92
Fig. 29: Removing the Air Inlets92
Removing the Gas Outlet Casing93
Removing the Gas Outlet Flange93
Fig. 30: Removing the Gas Outlet Casing93
Fig. 31: Dismantling the Gas Outlet Flange94
Table 32: 3 Press-Off Screws94
Fig. 32: Removing the Gas Outlet Flange95
Table 33: 6 Press-Off Screws95
Removing the Compressor Casing96
Fig. 33: Removing the Compressor Casing96
Fig. 34: Dismantling the Wall Insert97
Pressing off the Casing98
Fig. 35: Press off the Casing98
Removing the Cartridge Group99
Fig. 36: Oil Orifice99
Fig. 37: Removing Cartridge Group 199
Fig. 38: Removing Cartridge Group 2100
Removing the Nozzle Ring101
Fig. 39: Removing the Nozzle Ring101
Installing the Cartridge Group on the Service Support102
Fig. 40: Installing the Cartridge Group on the Service Support102
Measuring Clearance a and B103
Fig. 41: Measuring Clearance a and B103
Table 34: Permissible Clearances a and B103
Nozzle Ring Compression PD104
Fig. 42: Nozzle Ring Compression PD104
Table 35: Nozzle Ring Compression PD104
Installing the Nozzle Ring105
Fig. 43: Installing the Nozzle Ring105
Installing the Cartridge Group106
Fig. 44: Measuring the End Position of the Nozzle Ring106
Fig. 45: Lifting the Cartridge Group and Rotating It106
Table 36: End Position of the Nozzle Ring, Control Dimension H106
Fig. 46: Installing the Cartridge Group107
Table 37: Tightening Torque (51007)107
Installing the Compressor Casing108
Fig. 47: Fitting the Wall Insert and the Diffuser108
Fig. 48: Installing the Compressor Casing108
Table 38: Tightening Torque (79041)108
Table 39: Tightening Torque (72011)109
Measuring Radial Clearances N and R110
Fig. 49: Measuring Clearances N and R110
Table 40: Permissible Clearances N and R110
Installing the Air Inlets111
Fig. 50: Installing the Air Inlets111
Table 41: Tightening Torque (72020)111
Installing the Gas Outlet Flange112
Installing the Gas Outlet Casing112
Fig. 51: Installing the Gas Outlet Flange112
Fig. 52: Installing the Gas Outlet Casing112
Table 42: Tightening Torque (51009)112
Table of Tightening Torques113
Fig. 53: Tightening Torques113
Table 43: Tightening Torques of the Screw Fittings113
Taking out of Operation at Short Notice114
Possible Emergency Repairs114
Installing the Replacement Turbocharger115
Installing the Replacement Cartridge Group115
Mothballing the Turbocharger116
Taking the Engine out of Operation for up to 12 Months116
Taking the Engine out of Operation for more than 12 Months117
Disposing of Turbocharger Components118
Spare Parts119
Ordering Spare Parts119
Required Customer Spare Part Set (97070)119
Table 44: Customer Spare Part Set 97070119
View of Turbocharger with Part Numbers120
Fig. 54: Overview of Part Numbers120
Table 45: Spare Parts List121
Figures122

ABB HT845527 - Page 10

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