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ABB VTR354P11 - User Manual

ABB VTR354P11
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Operation Manual
ABB Turbocharging

ABB Turbo Systems Ltd
CH 5401 Baden
Type VTR354P11 HT842999
n
Mmax
408 t
Mmax
650
n
Bmax
0 t
Bmax
0
1/s °C
01800 12 50 100
Year 2017
made in Switzerland
Application according to
the Operation Manual
kg
HZTL2120 English
VTR354P11
Original Operation Manual

Table of Contents

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Summary

Preliminary Remarks

Foreword

Introduction to the operation manual and its purpose.

Mode of Operation

Explanation of how the turbocharger functions.

Correct Application

Guidelines for the intended and proper use of the turbocharger.

Organizational Measures

Requirements for safe handling and environmental protection.

Original Parts and Safety

Importance of using genuine parts and associated safety.

Qualification of Personnel

Specifies the necessary skills for operating and maintaining the turbocharger.

After-Sales Service

Information on ordering spare parts and accessing service.

Storage of New Turbochargers

Guidelines for storing turbochargers before installation.

Abbreviations

List of abbreviations used in the manual.

Rating Plate Turbocharger

Explanation of information found on the turbocharger's rating plate.

Instructions on Safety and Hazards

Safety

General safety principles and introduction to hazards.

Introduction to Safety

Overview of safety measures and potential risks.

Definition of Safety Instructions

Explanation of symbols and terms related to safety.

Warning Plates on the Turbocharger

Identification and meaning of warning labels on the unit.

Safe Operation and Maintenance

Instructions for safe use and upkeep of the turbocharger.

General Work and Area Safety

Guidelines for ensuring safety in the work environment.

Welding Work Safety

Specific safety precautions for welding activities near the turbocharger.

Safety During Commissioning and Operation

Procedures for safe startup and ongoing operation.

Safety During Cleaning

Precautions to be taken when cleaning the turbocharger.

Safety During Disassembly, Assembly, and Maintenance

Safety guidelines for all service and repair tasks.

Safety During Shutdown and Mothballing

Procedures for safely taking the turbocharger out of service.

Hazards During Operation and Maintenance

Identification of risks associated with the turbocharger's operation.

Mechanical Hazards During Operation

Risks from moving parts and mechanical failures during use.

Mechanical Hazards During Service

Risks from mechanical components during maintenance.

Hazards Due to Noise

Information on noise levels and hearing protection.

Hazards Due to Hot Surfaces

Precautions regarding burns from hot components and materials.

Hazards from Operating Materials

Risks associated with lubricants, cleaning agents, and other materials.

Hazards from Insulating Materials

Safety guidelines for handling insulation materials.

Hazards from Electrical Components

Risks related to electrical parts and components.

Handling Loads Safely

Procedures for safely lifting and moving turbocharger components.

Putting into Operation

Lubricating Oil Information

Details on lubricating oil requirements and classifications.

Lubricating Oil Quantities

Table specifying oil volumes for different turbocharger models.

Lubricating Oil Classifications

Categorization of oils based on viscosity and type.

Filling Lubricating Oil

Instructions for correctly filling the oil spaces.

Draining the Gas Outlet Casing

Procedure for draining moisture from the gas outlet casing.

Cooling Water System

Information on the turbocharger's cooling water system.

Cooling Water Temperatures

Specifications for water temperatures in the cooling system.

Inspection Before Operation

Checks required before the turbocharger is put into service.

Outline of Inspection Work

Overview of inspection points, symbols, and intervals.

Pre-Operation Inspection

Detailed checks to be performed before initial startup.

Post-Operation Inspection

Checks to be performed after the turbocharger has been run.

Inspection After 100 Hours

Scheduled inspection after 100 hours of operation.

Inspection After 50-100 Hours

Scheduled inspection within the 50-100 hour range.

Operation and Maintenance

Inspection Procedures

Overview of visual checks, monitoring, and measurements during operation.

Outline of Inspection Work

Visual guide to inspection points and intervals.

Inspection Every 25-50 Hours

Detailed inspection tasks for 25-50 hour intervals.

Inspection Every 100 Hours

Scheduled inspection tasks for 100 hour intervals.

Inspection With Every Service

Checks to be performed during routine servicing.

Machine Logbook Entries

Data to be recorded in the machine logbook for performance monitoring.

Monitoring Turbocharger Performance

Methods and devices for monitoring turbocharger operation.

Speed Measurement

Procedures and interpretation of turbocharger speed readings.

U-tube Manometer Usage

Using the U-tube manometer to check filter contamination.

Turbocharger Surging

Understanding and addressing turbocharger surging phenomena.

Contact with Rotating Parts

Safety regarding wear on rotating components.

Cleaning Procedures

Instructions and safety for cleaning turbocharger components.

Safety Instructions for Cleaning

Essential safety precautions when using cleaning agents.

Outline of Cleaning Work

Visual guide to cleaning points and intervals.

Cleaning the Air Filter

Step-by-step guide for cleaning air filter segments.

Cleaning Cooling Water Spaces

Procedure for cleaning cooling water passages and air ducts.

Cleaning the Oil Spaces

Instructions for cleaning the turbine and compressor end oil spaces.

Cleaning the Turbine

Methods for cleaning the turbocharger turbine during operation.

Cleaning the Compressor

Procedure for cleaning the compressor stage with water.

Maintenance Work Overview

General information on maintenance tasks and intervals.

Outline of Maintenance Work

Visual guide to maintenance points and intervals.

Changing the Lubricating Oil

Procedure and intervals for changing the lubricating oil.

Bearing Replacement Intervals

When to replace turbocharger bearings.

Compressor Wheel Replacement

When to replace the compressor wheel.

Bladed Shaft Replacement

When to replace the turbocharger's bladed shaft.

Troubleshooting

Troubleshooting Guide

Identifies common problems, their causes, and recommended remedies.

Disassembly and Assembly

Introduction to Disassembly and Assembly

General information and safety precautions for service procedures.

Turbocharger Weights

Weights of turbocharger components for handling and lifting.

Removing and Installing the Turbocharger

Procedure for detaching and refitting the turbocharger.

Removing and Installing Bearings

Detailed steps for bearing removal and installation.

Removing Compressor End Bearing

Specific instructions for removing the compressor side bearing.

Removing Turbine End Bearing

Specific instructions for removing the turbine side bearing.

Installing Turbine End Bearing

Steps for installing the turbine side bearing correctly.

Installing Compressor End Bearing

Steps for installing the compressor side bearing correctly.

Dimensions and Clearances

Measurements and tolerances for rotor and bearing assembly.

Removing and Installing the Rotor

Procedure for disassembling and assembling the turbocharger rotor.

Removing the Rotor

Detailed steps for removing the rotor assembly.

Replacing the Turbine Blades

Procedure for replacing damaged turbine blades.

Replacing the Compressor

Procedure for replacing the turbocharger compressor.

Installing the Rotor

Steps for correctly installing the rotor assembly.

Replacing the Cover Ring

Procedure for replacing the cover ring on the turbocharger.

Replacing the Nozzle Ring

Procedure for replacing the turbocharger's nozzle ring.

Lifting Air Outlet Casing

Instructions for safely lifting the air outlet casing.

Lifting Gas Outlet Casing

Instructions for safely lifting the gas outlet casing.

Lifting Gas Inlet Casing

Instructions for safely lifting the gas inlet casing.

Lifting the Foot

Instructions for safely lifting the turbocharger's foot.

Reserve Parts Management

Guidelines for maintaining and using spare parts.

Table of Tightening Torques

Specifications for screw tightening torques.

Taking Out of Operation

Shutting Down the Turbocharger

Procedure for safely shutting down the turbocharger.

Fitting the Blanking Device

Steps for installing a blanking device for shutdown.

Locking the Turbine End

Methods to secure the turbine end during shutdown.

Installing the Locking Device

Procedure for fitting the turbine end locking mechanism.

Removing the Locking Device

Procedure for removing the turbine end locking mechanism.

Mothballing the Turbocharger

Steps for long-term storage and protection.

Shutdown Up to 12 Months

Procedure for taking the turbocharger out of service for up to 12 months.

Shutdown Over 12 Months

Procedure for taking the turbocharger out of service for more than 12 months.

Appendix

Spare Parts Information

Overview of available spare parts for the turbocharger.

Ordering Spare Parts

Information required when ordering spare parts.

Illustration Numbering System

Explanation of the numbering system used for diagrams.

Directory of Part Numbers

List of part numbers for turbocharger components.

Turbocharger Part Numbers

Specific part numbers for turbocharger assemblies.

Tools for Service

List of tools supplied or available for turbocharger maintenance.

Blanking Device Components

Details and dimensions of parts for the blanking device.

Locking Device Components

Details of parts for the turbine end locking device.

Mothballing Components

Parts required for long-term storage and protection.

Approved Lubricating Oils

List 1 Mineral Oils

List of mineral oils and their change intervals.

List 2 Special Mineral and Synthetic Oils

List of special mineral and synthetic oils and their change intervals.

List 3 Synthetic Lubricating Oils

List of synthetic oils and their change intervals.

Guide to Service Stations

Summary

Preliminary Remarks

Foreword

Introduction to the operation manual and its purpose.

Mode of Operation

Explanation of how the turbocharger functions.

Correct Application

Guidelines for the intended and proper use of the turbocharger.

Organizational Measures

Requirements for safe handling and environmental protection.

Original Parts and Safety

Importance of using genuine parts and associated safety.

Qualification of Personnel

Specifies the necessary skills for operating and maintaining the turbocharger.

After-Sales Service

Information on ordering spare parts and accessing service.

Storage of New Turbochargers

Guidelines for storing turbochargers before installation.

Abbreviations

List of abbreviations used in the manual.

Rating Plate Turbocharger

Explanation of information found on the turbocharger's rating plate.

Instructions on Safety and Hazards

Safety

General safety principles and introduction to hazards.

Introduction to Safety

Overview of safety measures and potential risks.

Definition of Safety Instructions

Explanation of symbols and terms related to safety.

Warning Plates on the Turbocharger

Identification and meaning of warning labels on the unit.

Safe Operation and Maintenance

Instructions for safe use and upkeep of the turbocharger.

General Work and Area Safety

Guidelines for ensuring safety in the work environment.

Welding Work Safety

Specific safety precautions for welding activities near the turbocharger.

Safety During Commissioning and Operation

Procedures for safe startup and ongoing operation.

Safety During Cleaning

Precautions to be taken when cleaning the turbocharger.

Safety During Disassembly, Assembly, and Maintenance

Safety guidelines for all service and repair tasks.

Safety During Shutdown and Mothballing

Procedures for safely taking the turbocharger out of service.

Hazards During Operation and Maintenance

Identification of risks associated with the turbocharger's operation.

Mechanical Hazards During Operation

Risks from moving parts and mechanical failures during use.

Mechanical Hazards During Service

Risks from mechanical components during maintenance.

Hazards Due to Noise

Information on noise levels and hearing protection.

Hazards Due to Hot Surfaces

Precautions regarding burns from hot components and materials.

Hazards from Operating Materials

Risks associated with lubricants, cleaning agents, and other materials.

Hazards from Insulating Materials

Safety guidelines for handling insulation materials.

Hazards from Electrical Components

Risks related to electrical parts and components.

Handling Loads Safely

Procedures for safely lifting and moving turbocharger components.

Putting into Operation

Lubricating Oil Information

Details on lubricating oil requirements and classifications.

Lubricating Oil Quantities

Table specifying oil volumes for different turbocharger models.

Lubricating Oil Classifications

Categorization of oils based on viscosity and type.

Filling Lubricating Oil

Instructions for correctly filling the oil spaces.

Draining the Gas Outlet Casing

Procedure for draining moisture from the gas outlet casing.

Cooling Water System

Information on the turbocharger's cooling water system.

Cooling Water Temperatures

Specifications for water temperatures in the cooling system.

Inspection Before Operation

Checks required before the turbocharger is put into service.

Outline of Inspection Work

Overview of inspection points, symbols, and intervals.

Pre-Operation Inspection

Detailed checks to be performed before initial startup.

Post-Operation Inspection

Checks to be performed after the turbocharger has been run.

Inspection After 100 Hours

Scheduled inspection after 100 hours of operation.

Inspection After 50-100 Hours

Scheduled inspection within the 50-100 hour range.

Operation and Maintenance

Inspection Procedures

Overview of visual checks, monitoring, and measurements during operation.

Outline of Inspection Work

Visual guide to inspection points and intervals.

Inspection Every 25-50 Hours

Detailed inspection tasks for 25-50 hour intervals.

Inspection Every 100 Hours

Scheduled inspection tasks for 100 hour intervals.

Inspection With Every Service

Checks to be performed during routine servicing.

Machine Logbook Entries

Data to be recorded in the machine logbook for performance monitoring.

Monitoring Turbocharger Performance

Methods and devices for monitoring turbocharger operation.

Speed Measurement

Procedures and interpretation of turbocharger speed readings.

U-tube Manometer Usage

Using the U-tube manometer to check filter contamination.

Turbocharger Surging

Understanding and addressing turbocharger surging phenomena.

Contact with Rotating Parts

Safety regarding wear on rotating components.

Cleaning Procedures

Instructions and safety for cleaning turbocharger components.

Safety Instructions for Cleaning

Essential safety precautions when using cleaning agents.

Outline of Cleaning Work

Visual guide to cleaning points and intervals.

Cleaning the Air Filter

Step-by-step guide for cleaning air filter segments.

Cleaning Cooling Water Spaces

Procedure for cleaning cooling water passages and air ducts.

Cleaning the Oil Spaces

Instructions for cleaning the turbine and compressor end oil spaces.

Cleaning the Turbine

Methods for cleaning the turbocharger turbine during operation.

Cleaning the Compressor

Procedure for cleaning the compressor stage with water.

Maintenance Work Overview

General information on maintenance tasks and intervals.

Outline of Maintenance Work

Visual guide to maintenance points and intervals.

Changing the Lubricating Oil

Procedure and intervals for changing the lubricating oil.

Bearing Replacement Intervals

When to replace turbocharger bearings.

Compressor Wheel Replacement

When to replace the compressor wheel.

Bladed Shaft Replacement

When to replace the turbocharger's bladed shaft.

Troubleshooting

Troubleshooting Guide

Identifies common problems, their causes, and recommended remedies.

Disassembly and Assembly

Introduction to Disassembly and Assembly

General information and safety precautions for service procedures.

Turbocharger Weights

Weights of turbocharger components for handling and lifting.

Removing and Installing the Turbocharger

Procedure for detaching and refitting the turbocharger.

Removing and Installing Bearings

Detailed steps for bearing removal and installation.

Removing Compressor End Bearing

Specific instructions for removing the compressor side bearing.

Removing Turbine End Bearing

Specific instructions for removing the turbine side bearing.

Installing Turbine End Bearing

Steps for installing the turbine side bearing correctly.

Installing Compressor End Bearing

Steps for installing the compressor side bearing correctly.

Dimensions and Clearances

Measurements and tolerances for rotor and bearing assembly.

Removing and Installing the Rotor

Procedure for disassembling and assembling the turbocharger rotor.

Removing the Rotor

Detailed steps for removing the rotor assembly.

Replacing the Turbine Blades

Procedure for replacing damaged turbine blades.

Replacing the Compressor

Procedure for replacing the turbocharger compressor.

Installing the Rotor

Steps for correctly installing the rotor assembly.

Replacing the Cover Ring

Procedure for replacing the cover ring on the turbocharger.

Replacing the Nozzle Ring

Procedure for replacing the turbocharger's nozzle ring.

Lifting Air Outlet Casing

Instructions for safely lifting the air outlet casing.

Lifting Gas Outlet Casing

Instructions for safely lifting the gas outlet casing.

Lifting Gas Inlet Casing

Instructions for safely lifting the gas inlet casing.

Lifting the Foot

Instructions for safely lifting the turbocharger's foot.

Reserve Parts Management

Guidelines for maintaining and using spare parts.

Table of Tightening Torques

Specifications for screw tightening torques.

Taking Out of Operation

Shutting Down the Turbocharger

Procedure for safely shutting down the turbocharger.

Fitting the Blanking Device

Steps for installing a blanking device for shutdown.

Locking the Turbine End

Methods to secure the turbine end during shutdown.

Installing the Locking Device

Procedure for fitting the turbine end locking mechanism.

Removing the Locking Device

Procedure for removing the turbine end locking mechanism.

Mothballing the Turbocharger

Steps for long-term storage and protection.

Shutdown Up to 12 Months

Procedure for taking the turbocharger out of service for up to 12 months.

Shutdown Over 12 Months

Procedure for taking the turbocharger out of service for more than 12 months.

Appendix

Spare Parts Information

Overview of available spare parts for the turbocharger.

Ordering Spare Parts

Information required when ordering spare parts.

Illustration Numbering System

Explanation of the numbering system used for diagrams.

Directory of Part Numbers

List of part numbers for turbocharger components.

Turbocharger Part Numbers

Specific part numbers for turbocharger assemblies.

Tools for Service

List of tools supplied or available for turbocharger maintenance.

Blanking Device Components

Details and dimensions of parts for the blanking device.

Locking Device Components

Details of parts for the turbine end locking device.

Mothballing Components

Parts required for long-term storage and protection.

Approved Lubricating Oils

List 1 Mineral Oils

List of mineral oils and their change intervals.

List 2 Special Mineral and Synthetic Oils

List of special mineral and synthetic oils and their change intervals.

List 3 Synthetic Lubricating Oils

List of synthetic oils and their change intervals.

Guide to Service Stations

ABB VTR354P11 Specifications

General IconGeneral
BrandABB
ModelVTR354P11
CategoryBattery Charger
LanguageEnglish

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