Abb A175-M62 Axial Turbocharger Manuals

Table of Contents

3

Operation Manual / A170-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

Registered Trademarks

7

Layout and Function of the Turbocharger

8

Fig. 2: Layout and Function

8

Fig. 3: Connection of the Compressor Wheel Cooling

9

Symbols, Definitions

10

Table 1: Definition of Pictograms

11

Fig. 4: Volatile Corrosion Inhibitor (VCI)

12

Storage of New Turbochargers and Spare Parts

12

Fig. 5: 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

Periodic Check of the Pressure Vessels

17

Warning Plates on the Turbocharger

18

Fig. 6: Warning Plates on the Turbocharger

18

Fig. 7: Rating Plate

19

Turbocharger Rating Plate

19

Fig. 8: Locations of the Rating Plates

20

Lifting of Loads

21

Fig. 9: Attachment of Loads on the Crane Hook

21

Fig. 10: Attachment Angle

21

Prerequisites for Operation and Maintenance

22

Hazards During Operation and Maintenance

23

Safe Operation

25

Safe Maintenance

26

Removal and Installation

30

Turbocharger Weight

30

Fig. 11: Turbocharger Suspension Points

30

Table 4: Weight of Complete Turbocharger Unit

30

Fig. 12: Turbocharger Suspension Points

31

Removing the Turbocharger

31

Fig. 13: Removing the Foot Mounting

32

Fig. 14: Loosening the Clamping Nut

33

Installing the Turbocharger

34

Fig. 15: Turbocharger Suspension Points

34

Fig. 16: Removing Auxiliary Screw

35

Fig. 17: Compressor-End Foot

35

Fig. 18: Turbine-End Foot

36

Table 5: Foot Screws, Dimension and Strength Class

36

Table 6: Foot Screws, Dimension CE

36

Table 7: Foot Screws, Dimension te

36

Table 8: Foot Screws, Number of Cup Springs

36

Fig. 19: CE Foot Contact Surface

37

Fig. 20: te Foot: Handling of Cup Spring Contact Surface / Foot Contact Surface

37

Fig. 21: Tightening the Foot Screws (1)

38

Fig. 22: Tightening Procedure

39

Table 9: Torque-Controlled Tightening of the Pressure Screws

39

Commissioning

40

Oil Supply

40

Inspection Procedures

41

Commissioning after Taking out of Operation

42

Monitoring During Operation

43

Oil Pressure, Oil Temperature

43

Fig. 23: Lubricating Oil Pressure Measuring Point

43

Table 10: Oil Pressure Range

43

Table 11: Oil Temperature at the Inlet

44

Table 12: Oil Temperature at the Outlet

44

Turbocharger Speed

45

Fig. 24: Speed Measurement

45

Noise Emission

48

Operation and Service

48

Fig. 25: Noise Insulation, Bellows

49

Service Work

50

Expected Replacement Intervals

53

Stopping the Engine

54

Table 13: Expected Replacement Intervals

54

Table 14: Recommended Replacement Intervals

54

Periodic Maintenance

55

Foreword to Maintenance

55

Cleaning the Filter Silencer

56

Fig. 26: Cleaning the Filter Silencer

56

Fig. 27: Cleaning the Filter Silencer (2)

58

Table 15: Tightening Torque (81272)

58

Table 16: Tightening Torque (81273)

58

Cleaning the Slotted Diffuser

59

Fig. 28: Cleaning the Slotted Diffuser

59

Cleaning the Compressor During Operation

60

Table 17: Compressor Cleaning Parameters

62

Fig. 29: Operation of Water Pressure Vessel

64

Table 18: Compressor Cleaning Parameters

65

Cleaning Turbine and Nozzle Ring

66

Fig. 30: Turbine and Nozzle Ring Cleaning Cycle

68

Fig. 31: Cleaning Cycle of Turbine and Nozzle Ring with Load Ramp

69

Fig. 32: Procedure Wet Cleaning of Turbine and Nozzle Ring

70

Table 19: Cleaning Parameters Wet Cleaning of Turbine and Nozzle Ring

71

Table 21: Malfunctions When Starting - Vibrations

72

Table 22: Malfunctions When Starting - Rubbing of Rotating Parts

72

Table 20: Malfunctions When Starting - Delayed Start-Up

72

Malfunctions When Starting

72

Troubleshooting

72

Malfunctions During Operation

73

Table 23: Malfunctions During Operation - Lubricating Oil Pressure too Low

73

Table 24: Malfunctions During Operation - Drop in Speed

73

Table 25: Malfunctions During Operation - Speed Increases

73

Table 26: Malfunctions During Operation - Exhaust Gas Temperature too High

74

Table 27: Malfunctions During Operation - Charge Air Pressure too Low

74

Surging of the Turbocharger

75

Table 28: Malfunctions During Operation - Charge Air Pressure too High

75

Table 29: Surging of the Turbocharger

75

Malfunctions When Stopping

76

Table 30: Malfunctions When Stopping - Runout Noises

76

Table 31: Malfunctions When Stopping - Shortened Runout Time

76

Table 34: Malfunction, Measured Speed too Low

77

Table 33: Malfunction, Measured Speed too High

77

Table 32: Malfunction, no Speed Measurement Signal or Poor Signal Amplitude

77

Speed Measurement System

77

Disassembly and Assembly

78

Introduction

78

Weight of Assemblies

80

Fig. 33: Weight of Assemblies

80

Table 35: Assembly Weights

80

Removing the Air Inlets

81

Fig. 34: Removing the Filter Silencer

81

Fig. 35: Removing the Air Suction Branch

82

Axial Clearance a Prior to Disassembly

83

Fig. 36: Axial Clearance

83

Table 36: Axial Clearance a

83

Fig. 37: Removing Wall Insert

84

Removing the Compressor Casing

84

Fig. 38: Transporting and Turning Wall Insert

85

Fig. 39: Removing the Diffuser

86

Fig. 40: Removing the Compressor Casing

87

Removing the Cartridge Group

88

Fig. 41: Safety-Relevant Screws

88

Fig. 42: Removing Cartridge Group 1

89

Fig. 43: Removing Cartridge Group 2

90

Removing the Nozzle Ring

91

Fig. 44: Removing Turbine Diffuser 1

91

Fig. 45: Removing Turbine Diffuser 2

92

Fig. 46: Removing Cover Ring 1

93

Fig. 47: Removing Cover Ring 2

94

Fig. 48: Removing Nozzle Ring 1

94

Fig. 49: Removing Nozzle Ring 2

95

Installing the Nozzle Ring

96

Fig. 50: Installing Nozzle Ring 1

96

Fig. 51: Installing Nozzle Ring 2

97

Table 37: Tightening Torque (56014)

97

Fig. 52: Installing Cover Ring

98

Table 38: Tightening Torque (57005)

98

Fig. 53: Installing Turbine Diffuser 1

99

Fig. 54: Installing Turbine Diffuser 2

100

Table 39: Tightening Torque (61069)

100

Installing the Cartridge Group

101

Fig. 55: Installing the Cartridge Group 1

101

Fig. 56: Installing the Cartridge Group 2

102

Fig. 57: Installing the Cartridge Group 3

102

Table 40: Tightening Torque (61059 / 42128)

102

Table 41: Tightening Torque (86505)

103

Fitting the Spinner Nose Cone

104

Fig. 58: Preparing the Threaded Stud (25008)

104

Table 42: Inner Thread Size (25008)

104

Fig. 59: Fitting the Spinner Nose Cone (25012)

105

Table 43: Tightening Torque (25013)

105

Installing the Compressor Casing

106

Fig. 60: Installing the Compressor Casing

106

Table 44: Tightening Torque (61037)

106

Table 45: Tightening Torque, Nuts that Are Difficult

106

Table 46: Tightening Torque (61090)

106

Fig. 61: Installing Diffuser

107

Table 47: Tightening Torque (77015)

107

Fig. 62: Turning and Moving in Wall Insert

108

Table 48: Tightening Torque (72011)

109

Fig. 63: Fitting Wall Insert

109

Axial Clearance a after Assembly

110

Fig. 64: Axial Clearance

110

Table 49: Axial Clearance a

110

Installing the Air Inlets

111

Fig. 65: Installing the Air Suction Branch

111

Table 50: Tightening Torque (72027)

111

Fig. 66: Installing the Filter Silencer

112

Table 51: Tightening Torque (72027)

112

Removing and Installing Turbine-End Nozzle Ring

114

Fig. 67: Removing the Nozzle Ring at the Turbine End (Radial Gas Inlet Casing)

115

Fig. 68: Removing the Nozzle Ring at the Turbine End (Axial Gas Inlet Casing)

115

Fig. 69: Installing the Nozzle Ring at the Turbine End (Radial Gas Inlet Casing)

116

Fig. 70: Installing the Nozzle Ring at the Turbine End (Axial Gas Inlet Casing)

116

Table 52: Tightening Torque (56014)

117

Table 53: Tightening Torque (61009)

117

Table of Tightening Torques

118

Fig. 71: Tightening Torques 1

118

Fig. 72: Tightening Torques 2

118

Table 54: Tightening Torques

119

Fig. 73: Flange Tightening Sequence

120

Table 55: Tightening Torques 61009

120

Taking a Turbocharger out of Operation

121

Possible Emergency Repairs

121

Locking the Rotor

122

Fig. 74: Fitting the Locking Device

123

Table 56: Locking Device Tightening Torque

123

Table 59: Cover Plate Dimensions 3

125

Table 58: Cover Plate Dimensions 2

125

Fig. 76: Fitting the Cover Plate

125

Table 57: Cover Plate Dimensions 1

125

Fig. 75: Cover Plate (01) / Spacer Sleeves (02) Dimensions

125

Fitting the Cover Plate

125

Blanking off the Inlets and Outlets

127

Engines with Bypass Around the Turbocharger

127

Mothballing the Turbocharger

128

Taking the Engine out of Operation for up to 12 Months

128

Taking the Engine out of Operation for more than 12 Months

129

Material and Disposal

130

REACH and Rohs Compliance Declaration for Products

130

Disposing of Turbocharger Components

131

Spare Parts

132

Ordering Spare Parts

132

Table 60: Customer Spare Part Set (97070)

132

Spare Part - Illustrations

133

Table 61: Spare Parts - Cartridge

133

Table 62: Spare Parts - Bearing Casing

134

Table 63: Spare Parts - Rotor and Bearing Parts

135

Table 64: Spare Parts - Water Vessel

136

Table 65: Spare Parts - Gas Inlet Casing Axial

137

Table 66: Spare Parts - Gas Inlet Casing Radial

138

Table 67: Spare Parts - Cleaning Device for Gas Inlet Casing

139

Table 68: Spare Parts - Compressor Casing

140

Table 69: Spare Parts - Filter Silencer

141

Table 70: Spare Parts - Air Suction Branch Radial

142

Tools

143

Table 71: Customer Tool Set 90009

143

ABB A175-M62 Axial Turbocharger Manuals

Table of Contents

Operation Manual / A170-M - A175-M

Table of Contents

Operation Manual / A170-M - A175-M

Table of Contents

Operation Manual / A170-M - A175-M

1 Introduction

2 Safety

3 Removal and Installation

4 Commissioning

5 Monitoring During Operation

6 Operation and Service

7 Periodic Maintenance

8 Troubleshooting

9 Disassembly and Assembly

10 Taking a Turbocharger out of Operation

11 Mothballing the Turbocharger

12 Disposing of Turbocharger Components

13 Spare Parts

14 Tools

Table of Contents

Operation Manual / A170-M - A175-M

Table of Contents

Operation Manual / A170-M - A175-M

Table of Contents

Operation Manual / A170-M - A175-M

Table of Contents

Operation Manual / A170-M - A175-M

Table of Contents

Operation Manual / A170-M - A175-M

Table of Contents

Operation Manual / A170-M - A175-M

Table of Contents

Operation Manual / A170-M - A175-M

Table of Contents

Introduction

Safety

Product Description

Table of Contents

Introduction

Safety

Product Description

Table of Contents

Introduction

Safety

Product Description

Table of Contents

Introduction

Safety

Product Description

Table of Contents

Introduction

Safety

Product Description

1 Introduction

2 Removal and Installation

3 Commissioning

4 Monitoring During Operation

5 Operation and Service

6 Periodic Maintenance

7 Troubleshooting

8 Disassembly and Assembly

Table of Contents

Introduction

Safety

Product Description

Table of Contents

Introduction

Safety

Product Description

Table of Contents

Introduction

Safety

Product Description

Table of Contents

Introduction

Safety

Product Description

Table of Contents