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Battery Charger
A130-H57
ABB A130-H57 User Manual
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Operation Manual / 4 Product description / A130-H.. - A140-H
3 Commissioning / 3.1 Oil supply
© Copyright 2017 ABB. All rights reserved.
HZTL4030_EN
Revision D
May 2017
3.1.5
Oil orifice in the bearing casing
Fig.17: Oil orifice
01
Bearing casing
02
Oil orifice
03
Circlip
With an oil inlet pressure of more than 3 bar (with engine under load) before the turbochar-
ger, the bearing casings are equipped as standard with an orifice at the oil inlet.
Page 21 / 91
50
52
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
25
Copyright 2017 ABB. All Rights Reserved. HZTL4022_EN Revision E May
26
Product Description
31
1 Introduction
33
Essential Information
33
Registered Trademarks
33
Related Documents
33
Table 1: Related Documents
33
Contact Information
33
Layout and Function of the Turbocharger
34
Fig. 1: Layout and Function of the Turbocharger
34
Fig. 2: Compressor Wheel Cooling
35
Warning Plates on the Turbocharger
36
Fig. 3: Warning Plate Locations
36
Locations of the Rating Plates
37
Fig. 4: Locations of the Rating Plates
37
2 Removing and Installing
38
Turbocharger Weight and Transportation
38
Fig. 5: Suspension of Complete Turbocharger Unit
38
Table 2: Weights of Turbochargers A130-H
38
Removing the Turbocharger
39
Fig. 6: Removing the Turbocharger
39
Fig. 7: Loosening the Clamping Nut
41
Fig. 8: Putting down the Turbocharger
42
Installing the Turbocharger
43
Fig. 9: Inserting Gaskets into the Bracket
43
Fig. 10: Inserting the Threaded Rods
44
Fig. 11: Requirements for Threaded Rods
44
Table 3: Requirements for Threaded Rods
44
Fig. 12: Placing the Turbocharger on the Bracket
45
Table 4: Tightening Torques for Standard Nuts
46
Fig. 13: Preparing the Clamping Nut for the Tightening Procedure
47
Fig. 14: Tightening Pressure Screws
48
Table 5: Pressure Screw Tightening Torque
48
Fig. 15: Connecting the Compressor Cooling Air Intake
49
Fig. 16: Attaching the Support
49
3 Commissioning
50
Oil Supply
50
Fig. 17: Oil Orifice
51
Inspection Procedures
52
Commissioning after Taking out of Operation
54
4 Monitoring Operation
55
Oil Pressure, Oil Temperature
55
Table 6: Lubricating Oil Pressure at Oil Inlet before Turbocharger
55
Table 7: Lubricating Oil Temperature at the Inlet
56
Table 8: Lubricating Oil Temperature at the Outlet
56
Exhaust Gas Temperature before Turbine
57
Turbocharger Speed
58
Fig. 18: Layout and Overview of Speed Measurement System
58
Fig. 19: Replacing the Speed Sensor
60
Table 9: Tightening Torque (86505)
60
5 Operation and Service
61
Noise Emission
61
Fig. 20: Noise Insulation, Bellows
61
Service Work
63
Fig. 21: Replacing the Protective Grid
65
Expected Replacement Intervals
67
Table 10: Expected Replacement Intervals
67
Stopping the Engine
68
6 Periodic Maintenance Work
69
Foreword to Maintenance
69
Cleaning Components Mechanically
69
Fig. 22: Cleaning the Filter Silencer
70
Fig. 23: Compressor-End, Non-Rotating Parts
72
Fig. 24: Turbine End, Non-Rotating Parts
73
Fig. 25: Soaking the Turbine End
76
Table 11: Value Table for Soaking
76
7 Eliminating Malfunctions
79
Malfunctions When Starting
79
Table 12: Malfunctions When Starting - Delayed Start-Up
79
Table 13: Malfunctions When Starting - Vibrations
79
Table 14: Malfunctions When Starting - Rubbing of Rotating Parts
79
Malfunctions During Operation
80
Table 15: Malfunctions During Operation - Lubricating Oil Pressure too Low
80
Table 16: Malfunctions During Operation - Speed Reduces
80
Table 17: Malfunctions During Operation - Speed Increases
80
Table 18: Malfunctions During Operation - Exhaust Gas Temperature too High
81
Table 19: Malfunctions During Operation - Charge Air Pressure too Low
81
Table 20: Malfunctions During Operation - Charge Air Pressure too High
82
Table 21: Malfunctions During Operation - Engine Performance Losses
82
Turbocharger Is Surging
83
Table 22: Malfunction - Turbocharger Pumping
83
Table 23: Malfunction - Sporadic Surge Blows
83
Malfunctions When Stopping
84
Table 24: Malfunctions When Stopping - Runout Noises
84
Table 25: Malfunctions When Stopping - Runout Time too Short
84
Speed Measurement System
85
Table 26: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
85
Table 27: Malfunction of the Speed Measurement System - Measured Speed too High
85
Table 28: Malfunction of the Speed Measurement System - Measured Speed too Low
85
8 Dismantling and Fitting
86
Introduction
86
Table 29: Swivel Lifting Eyes
88
Table 30: Ring Nuts to be Used
88
Weights of Individual Parts
89
Fig. 26: Weights of Assemblies
89
Table 31: Weights of Assemblies
89
Removing Air Inlets
90
Fig. 27: Removing Air Inlets
90
Removing the Gas Outlet Casing
91
Fig. 28: Removing the Gas Outlet Casing
91
Removing the Gas Outlet Flange
92
Table 32: 3 Press-Off Screws
92
Fig. 29: Removing the Gas Outlet Flange
93
Table 33: 6 Press-Off Screws - Gas Outlet Flange
93
Removing the Compressor Casing
94
Fig. 30: Removing the Compressor Casing
94
Fig. 31: Dismantling the Wall Insert
95
Pressing off the Casing
96
Fig. 32: Press off the Casing
96
Removing the Cartridge Group
97
Fig. 33: Removing Insulation Sheets
97
Fig. 34: Oil Orifice
97
Fig. 35: Removing Cartridge Group 1
98
Fig. 36: Removing Cartridge Group 2
98
Removing the Nozzle Ring
99
Fig. 37: Removing the Nozzle Ring
99
Installing the Cartridge Group on the Service Support
100
Fig. 38: Installing the Cartridge Group on the Service Support
100
Axial Clearance a and Radial Clearance B
101
Fig. 39: Measuring Clearance a and B
101
Table 34: Permissible Clearances a and B
101
Nozzle Ring Compression PD
102
Fig. 40: Nozzle Ring Compression PD
102
Table 35: Permitted Nozzle Ring Compression PD
102
Installing Nozzle Ring
103
Fig. 41: Installing the Nozzle Ring
103
Installing the Cartridge Group
104
Fig. 42: Measuring the End Position of the Nozzle Ring
104
Fig. 43: Lifting the Cartridge Group and Rotating It
104
Table 36: End Position of the Nozzle Ring, Control Dimension H
104
Fig. 44: Installing the Cartridge Group
105
Table 37: Tightening Torque (51007)
105
Installing the Compressor Casing
106
Fig. 45: Fitting the Wall Insert and the Diffuser
106
Table 38: Tightening Torque (79041)
106
Fig. 46: Installing the Compressor Casing
107
Table 39: Tightening Torque (72011)
107
Radial Clearances N and R
108
Fig. 47: Measuring Clearances N and R
108
Table 40: Permissible Clearances N and R
108
Installing Air Inlets
109
Fig. 48: Installing the Air Inlets
109
Table 41: Tightening Torque (72020)
109
Installing the Gas Outlet Flange
110
Installing the Gas Outlet Casing
110
Fig. 49: Installing the Gas Outlet Flange
110
Fig. 50: Installing the Gas Outlet Casing
110
Table 42: Tightening Torque (51009)
110
Table of Tightening Torques
111
Fig. 51: Tightening Torques
111
Table 43: Tightening Torques of the Screw Fittings
111
9 Taking out of Operation at Short Notice
112
Possible Emergency Repairs
112
Installing a Replacement Turbocharger
113
Installing a Replacement Cartridge Group
113
10 Mothballing the Turbocharger
114
Taking the Engine out of Operation for up to 12 Months
114
Taking the Engine out of Operation for more than 12 Months
115
11 Disposing of Turbocharger Components
116
12 Spare Parts
117
Ordering Spare Parts
117
Required Customer Spare Part Set (97070)
117
Table 44: Customer Spare Part Set 97070
117
View of Turbocharger with Part Numbers
118
Fig. 52: Overview of Part Numbers
118
Table 45: Spare Parts List
119
Figures
120
5
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ABB A130-H57 Specifications
General
Brand
ABB
Model
A130-H57
Category
Battery Charger
Language
English
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