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ABB HT578105 manual available for free PDF download: Operation Manual
ABB HT578105 Operation Manual (130 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 25.64 MB
Table of Contents
Introduction
3
Table of Contents
3
Introduction
4
Purpose of the Manual
4
Symbols, Definitions
5
Storage of New Turbochargers and Spare Parts
7
Contact Information
9
Safety
11
CE Conformity
12
Introduction
12
Safety
12
Definition of Mandatory Signs
13
Definition of Safety Instructions
13
Intended Use
14
Deflagration on Gas Engines
15
Warning Plates on the Turbocharger
16
Turbocharger Rating Plate
17
Periodic Check of the Pressure Vessels
18
Lifting of Loads
19
Prerequisites for Operation and Maintenance
20
Hazards During Operation and Maintenance
21
Safe Operation
23
Safe Maintenance
24
Product Description
31
Essential Information
33
Introduction
33
Registered Trademarks
33
Related Documents
33
Table 1: Related Documents
33
Fig. 1: Layout and Function
34
Layout and Function of the Turbocharger
34
Fig. 2: Connection of the Compressor Wheel Cooling
35
Fig. 3: Warning Plates on the Turbocharger
36
Warning Plates on the Turbocharger
36
Fig. 4: Locations of the Rating Plates
37
Locations of the Rating Plates
37
Fig. 5: Turbocharger Suspension Points
38
Removal and Installation
38
Table 2: Weight of the Turbocharger
38
Turbocharger Weight
38
Fig. 6: Turbocharger Suspension Points
39
Removing the Turbocharger
39
Fig. 7: Removing the Foot Mounting
40
Fig. 8: Loosening the Clamping Nut
41
Fig. 9: Turbocharger Suspension Points
42
Installing the Turbocharger
42
Fig. 10: Removing Auxiliary Screw
43
Fig. 11: Compressor-End Foot
44
Fig. 12: Turbine-End Foot
44
Table 3: Foot Bolt Dimensions
44
Fig. 13: CE Foot Contact Surface
45
Fig. 14: te Foot: Handling of Cup Spring Contact Surface / Foot Contact Surface
45
Fig. 15: Tightening the Foot Bolts (1)
46
Fig. 16: Tightening the Clamping Nut (2)
47
Table 4: Clamping Screw Tightening Torques
47
Commissioning
48
Oil Supply
48
Inspection Procedures
49
Commissioning after Taking out of Operation
50
Fig. 17: Lubricating Oil Pressure Measuring Point
51
Monitoring During Operation
51
Oil Pressure, Oil Temperature
51
Table 5: Oil Pressure Range
51
Table 6: Oil Temperature at the Inlet
52
Table 7: Oil Temperature at the Outlet
52
Fig. 18: Speed Measurement
53
Turbocharger Speed
53
Noise Emission
56
Operation and Service
56
Fig. 19: Noise Insulation, Bellows
57
Service Work
58
Expected Replacement Intervals
61
Stopping the Engine
62
Table 8: Expected Replacement Intervals
62
Table 9: Recommended Replacement Intervals
62
Cleaning the Filter Silencer
63
Fig. 20: Cleaning the Filter Silencer (1)
63
Foreword to Maintenance
63
Periodic Maintenance
63
Fig. 21: Cleaning the Filter Silencer (2)
65
Table 10: Tightening Torque (81272)
65
Table 11: Tightening Torque (81273)
65
Cleaning the Slotted Diffuser
66
Fig. 22: Cleaning the Slotted Diffuser
66
Cleaning the Compressor During Operation
67
Table 12: Compressor Cleaning Parameters
69
Cleaning Turbine and Nozzle Ring
71
Fig. 23: Turbine and Nozzle Ring Cleaning Cycle
73
Fig. 24: Procedure Wet Cleaning of Turbine and Nozzle Ring
73
Table 13: Cleaning Parameters Wet Cleaning of Turbine and Nozzle Ring
74
Malfunctions When Starting
75
Table 14: Malfunctions When Starting - Delayed Start-Up
75
Table 15: Malfunctions When Starting - Vibrations
75
Table 16: Malfunctions When Starting - Rubbing of Rotating Parts
75
Troubleshooting
75
Malfunctions During Operation
76
Table 17: Malfunctions During Operation - Lubricating Oil Pressure too Low
76
Table 18: Malfunctions During Operation - Drop in Speed
76
Table 19: Malfunctions During Operation - Speed Increases
76
Malfunctions When Stopping
77
Surging of the Turbocharger
77
Table 20: Malfunctions When Stopping - Runout Noises
77
Table 21: Malfunctions When Stopping - Shortened Runout Time
77
Speed Measurement System
78
Table 22: Malfunction, no Speed Measurement Signal or Poor Signal Amplitude
78
Table 23: Malfunction, Measured Speed too High
78
Table 24: Malfunction, Measured Speed too Low
78
Disassembly and Assembly
79
Introduction
79
Weights of Assemblies
81
Fig. 25: Assemblies
81
Table 25: Assembly Weights
81
Fig. 26: Removing / Installing the Filter Silencer
82
Filter Silencer
82
Removing / Installing Air-Inlets
82
Table 26: Tightening Torque (27027)
82
Fig. 27: Removing / Installing the Air Suction Branch
83
Table 27: Tightening Torque (27027)
83
Axial Clearance a Prior to Disassembly
84
Fig. 28: Axial Clearance
84
Table 28: Axial Clearance
84
Compressor Casing
85
Fig. 29: Removing Wall Insert
85
Removing the Compressor Casing
85
Wall Insert
85
Fig. 30: Transporting and Turning Wall Insert
86
Fig. 31: Removing the Diffuser
87
Fig. 32: Remove Compressor Casing
88
Fig. 33: Safety-Relevant Screws
89
Removing the Cartridge Group
89
Fig. 34: Removing Cartridge Group 1
90
Fig. 35: Removing Cartridge Group 2
91
Fig. 36: Removing Turbine Diffuser 1
92
Fig. 37: Removing Turbine Diffuser 2
92
Removing Nozzle Ring
92
Turbine Diffuser
92
Cover Ring
93
Fig. 38: Removing Cover Ring 1
93
Fig. 39: Removing Cover Ring 2
93
Fig. 40: Removing Nozzle Ring 1
94
Fig. 41: Removing Nozzle Ring 2
94
Fig. 42: Installing Nozzle Ring 1
95
Installing Nozzle Ring
95
Fig. 43: Installing Nozzle Ring 2
96
Table 29: Tightening Torque (56014)
96
Fig. 44: Installing Cover Ring
97
Table 30: Tightening Torque (57005)
97
Fig. 45: Installing Turbine Diffuser 1
98
Fig. 46: Installing Turbine Diffuser 2
98
Table 31: Tightening Torque (61069)
98
Fig. 47: Installing the Cartridge Group 1
99
Installing the Cartridge Group
99
Fig. 48: Installing the Cartridge Group 2
100
Table 32: Tightening Torque (61059 / 42128 / 86505)
100
Fig. 49: Preparing the Threaded Stud (25008)
101
Table 33: Inner Thread Size (25008)
101
Fig. 50: Fitting the Spinner Nose Cone (25012)
102
Table 34: Tightening Torque (25013)
102
Fig. 51: Installing the Cartridge Group 3
103
Fig. 52: Installing the Compressor Casing
104
Installing the Compressor Casing
104
Table 35: Tightening Torque (61037 / 61090)
104
Fig. 53: Installing Diffuser
105
Table 36: Tightening Torque (77015)
105
Fig. 54: Turning and Moving in Wall Insert
106
Fig. 55: Fitting the Wall Insert
107
Table 37: Tightening Torque (72011)
107
Axial Clearance a after Assembly
108
Fig. 56: Axial Clearance
108
Table 38: Axial Clearance
108
Removing and Installing Turbine-End Nozzle Ring
109
Fig. 57: Removing the Nozzle Ring at the Turbine End
110
Fig. 58: Installing the Nozzle Ring at the Turbine End
111
Table 39: Tightening Torque (56014 / 61009)
111
Fig. 59: Tightening Torques 1
112
Fig. 60: Tightening Torques 2
112
Table of Tightening Torques
112
Table 40: Tightening Torques
113
Fig. 61: Flange Tightening Sequence
114
Table 41: Tightening Torques 61009
114
Possible Emergency Repairs
115
Taking a Turbocharger out of Operation
115
Locking the Rotor
116
Fig. 62: Fitting the Locking Device
117
Table 42: Locking Device Tightening Torque
117
Fig. 63: Cover Plate (01) / Spacer Sleeves (02) Dimensions
119
Fitting the Cover Plate
119
Table 43: Cover Plate Dimensions 1
119
Table 44: Cover Plate Dimensions 2
119
Table 45: Cover Plate Dimensions 3
119
Fig. 64: Fitting the Cover Plate
120
Blanking off the Inlets and Outlets
121
Engines with Bypass Around the Turbocharger
121
Mothballing the Turbocharger
122
Taking the Engine out of Operation for up to 12 Months
122
Taking the Engine out of Operation for more than 12 Months
123
Disposing of Turbocharger Components
124
Ordering Spare Parts
125
Spare Parts
125
Table 46: Customer Spare Part Set (97070)
125
Fig. 65: Turbocharger with Part Numbers
126
View of Turbocharger with Part Numbers
126
Table 47: Turbocharger with Part Numbers
127
Figures
128
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