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A155-M66
ABB A155-M66 User Manual
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Operation Manual / A150-M56/66/57/67 - A155-M..
10 Dismantling and fitting with removed air inlet and gas outlet / 10.6
Removing the cartridge group
© Copyright 2021 ABB. All rights reserved.
HZTL4032_EN
Rev.Q
January 2021
Fig.61: Removing cartridge group 3
7.
Place a suitable protective cover over the compressor wheel.
8.
Turn the cartridge group into the horizontal rotor axis.
9.
Remove lifting gear from service support and cross-piece.
Page 109 / 194
110
112
Table of Contents
Operation Manual / A150-M - A155-M
3
Table of Contents
3
Operation Manual / A150-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
Layout and Function of the Turbocharger
8
Fig. 2: Layout and Function of the Turbocharger
8
Fig. 3: Compressor Wheel Cooling
9
Symbols, Definitions
10
Table 1: Definition of Pictograms
11
Storage of New Turbochargers and Spare Parts
12
Fig. 4: Volatile Corrosion Inhibitor (VCI)
12
Fig. 5: Package with Hygrometer
13
Registered Trademarks
14
Safety
15
Introduction
15
CE Conformity
15
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
16
Table 2: Personal Protective Equipment to be Worn at All Times
16
Definition of Safety Instructions
16
Definition of Mandatory Signs
16
Intended Use
17
Warning Plates on the Turbocharger
18
Fig. 6: Warning Plate Locations
18
Turbocharger Rating Plate
19
Fig. 7: Rating Plate
19
Fig. 8: Locations of the Rating Plates
20
Periodic Check of the Pressure Vessels
21
Fig. 10: Attachment Angle
22
Fig. 9: Attachment of Loads on the Crane Hook
22
Lifting of Loads
22
Prerequisites for Operation and Maintenance
23
Hazards During Operation and Maintenance
24
Safe Operation
26
Safe Maintenance
27
Removing and Installing
31
Turbocharger Weight and Transportation
31
Fig. 11: Suspension of Complete Turbocharger Unit
31
Table 4: Weight of Complete Turbocharger Unit
31
Fig. 13: Removing the Turbocharger
32
Fig. 12: Turbine Cleaning Nozzle
32
Removing the Turbocharger
32
Fig. 14: Loosening the Clamping Nut
33
Fig. 15: Turbocharger Centre of Gravity
34
Installing the Turbocharger
35
Fig. 16: Inserting the Gasket
35
Fig. 17: Fitting the Turbocharger 1
36
Fig. 18: Fitting the Turbocharger 2
37
Table 5: Fitting the Turbocharger, Value X, L
37
Fig. 19: Preparing the Clamping Nut for the Tightening Procedure
38
Fig. 20: Tightening Pressure Screws
39
Table 6: Torque-Controlled Tightening of the Pressure Screws
39
Fig. 21: Connecting the Speed Sensor
40
Fig. 22: Connecting the Compressor Cooling Air Intake
40
Fig. 23: Attaching the Support
40
Commissioning
41
Oil Supply
41
Fig. 24: Oil Orifice
42
Inspection Procedures
43
Commissioning after Taking out of Operation
45
Table 7: Lubricating Oil Pressure at Oil Inlet before Turbocharger
46
Oil Pressure, Oil Temperature
46
Monitoring Operation
46
Table 8: Lubricating Oil Temperature at the Inlet
47
Table 9: Maximum Lubricating Oil Temperature at the Outlet
47
Exhaust Gas Temperature before Turbine
48
Turbocharger Speed
49
Fig. 25: Layout and Overview of Speed Measurement System
49
Fig. 26: Replacing the Speed Sensor
51
Table 10: Tightening Torque (86505)
51
Operation and Service
52
Noise Emission
52
Fig. 27: Noise Insulation, Bellows
53
Service Work
54
Expected Replacement Intervals
57
Table 11: Expected Replacement Intervals
57
Stopping the Engine
59
Periodic Maintenance Work
60
Foreword to Maintenance
60
Table 12: Maintenance Table
60
Cleaning the Compressor During Operation
61
Fig. 28: Carrying out Wet Cleaning of Compressor
63
Table 13: Parameters for Wet Cleaning of Compressor
63
Cleaning the Turbine During Operation
64
Fig. 29: Turbine Cleaning Devices
66
Table 14: Turbine Wet Cleaning, Recommended Operating State
66
Fig. 30: Carrying out Wet Cleaning of Turbines
67
Table 15: Wet Cleaning of Turbines, Parameters for 1-Nozzle Cleaning
67
Cleaning Components Mechanically
68
Table 16: Wet Cleaning of Turbines, Parameters for 6-Nozzle Cleaning
68
Fig. 31: Cleaning the Filter Silencer
69
Fig. 32: Compressor-End, Non-Rotating Parts
71
Fig. 33: Turbine End, Non-Rotating Parts
73
Table 17: Value Table for Soaking
75
Fig. 34: Soaking the Turbine End
75
Fig. 35: Disassembling the Absorption Element
78
Changing the Absorption Element
78
Fig. 36: Installing the Absorption Element
79
Table 18: Tightening Torque (81152 / 81154)
79
Eliminating Malfunctions
80
Malfunctions When Starting
80
Table 19: Malfunctions When Starting - Delayed Start-Up
80
Table 20: Malfunctions When Starting - Vibrations
80
Table 21: Malfunctions When Starting - Rubbing of Rotating Parts
80
Table 24: Malfunctions During Operation - Speed Increases
81
Malfunctions During Operation
81
Table 23: Malfunctions During Operation - Speed Reduces
81
Table 22: Malfunctions During Operation - Lubricating Oil Pressure too Low
81
Table 25: Malfunctions During Operation - Exhaust Gas Temperature too High
82
Table 26: Malfunctions During Operation - Charge Air Pressure too Low
82
Table 27: Malfunctions During Operation - Charge Air Pressure too High
83
Table 28: Malfunctions During Operation - Engine Performance Losses
83
Turbocharger Is Surging
84
Table 29: Malfunction - Turbocharger Pumping
84
Table 30: Malfunction - Sporadic Surge Blows
84
Table 32: Malfunctions When Stopping - Runout Time too Short
85
Malfunctions When Stopping
85
Table 31: Malfunctions When Stopping - Runout Noises
85
Speed Measurement System
86
Table 33: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
86
Table 34: Malfunction of the Speed Measurement System - Measured Speed too High
86
Table 35: Malfunction of the Speed Measurement System - Measured Speed too Low
86
Dismantling and Fitting, General
87
Introduction
87
Table 36: Swivel Lifting Eyes
88
Fig. 37: Swivel Lifting Eyes
88
Material Required
88
Fig. 38: Press-Off Screws
89
Fig. 39: Dismantling Screw
89
Table 37: Press-Off Screws
89
Table 38: Dismantling Screw
89
Disassembly and Assembly Concepts
91
Fig. 40: Removing the Cartridge Group with Compressor and Turbine Casing
91
Fig. 41: Cartridge Concept
92
Fig. 42: Optional Spanner Holder
93
Table 39: Weights of Assemblies
94
Fig. 43: Weights of Assemblies
94
Weights of Individual Parts
94
Table of Tightening Torques
95
Fig. 44: Overview of Tightening Torques
95
Table 40: Tightening Torques
95
Fig. 45: Tightening Torques for Insulation
96
Table 41: Tightening Torques for Insulation
96
Dismantling and Fitting with Removed Air Inlet and Gas Outlet
97
Removing Air Inlets
97
Fig. 46: Removing the Air Inlets
97
Fig. 47: Removing the Uncoupled Filter Silencer
98
Removing the Gas Outlet Casing
99
Fig. 48: Remove Gas Outlet Casing Without Support
99
Fig. 49: Removing Gas Outlet Casing with Support 1
100
Fig. 50: Removing Gas Outlet Casing with Support 1
101
Removing the Gas Outlet Flange
102
Fig. 51: Dismantling the Gas Outlet Flange
103
Table 42: 3 Press-Off Screws
103
Fig. 52: Removing the Gas Outlet Flange
104
Table 43: 6 Press-Off Screws
104
Fig. 54: Remove Insulation
105
Fig. 53: Turbine Cleaning Nozzle
105
Removing the Cartridge Group with Compressor and Turbine Casing
105
Fig. 55: Removing the Cartridge Group with Compressor and Turbine Casing
106
Fig. 56: Set down the Cartridge Group with the Compressor and Turbine Casing
106
Removing the Compressor Casing
107
Fig. 57: Removing the Compressor Casing
107
Fig. 58: Dismantling the Diffuser and the Wall Insert
108
Removing the Cartridge Group
109
Fig. 59: Removing Cartridge Group 1
109
Table 44: Tightening Torque (90012-01)
109
Fig. 60: Removing Cartridge Group 2
110
Fig. 61: Removing Cartridge Group 3
111
Fig. 62: Installing the Cartridge Group on the Service Support
112
Installing the Cartridge Group on the Service Support
112
Fig. 63: Removing the Nozzle Ring
113
Removing the Nozzle Ring
113
Fig. 64: Measuring Clearance a and B
114
Measuring Clearance a and B
114
Table 45: Permissible Clearances a and B
114
Fig. 65: Nozzle Ring Compression PD
115
Nozzle Ring Compression PD
115
Table 46: Nozzle Ring Compression PD
115
Fig. 66: Installing the Nozzle Ring
116
Installing Nozzle Ring
116
Fig. 67: Lifting the Cartridge Group and Rotating It by 90
117
Installing the Cartridge Group
117
A150
118
A155
118
Fig. 68: Turning the Cartridge Group
118
Table 47: Tightening Torque (90012-01)
118
Fig. 69: Installing the Cartridge Group
119
Table 48: Tightening Torque (51007)
119
Fig. 70: Fitting the Wall Insert and the Diffuser
120
Installing the Compressor Casing
120
Table 49: Tightening Torque (79041)
120
Fig. 71: Installing the Compressor Casing
121
Table 50: Tightening Torque (72011)
121
Fig. 72: Turning the Cartridge Group with Compressor and Turbine Casing
122
Turning the Cartridge Group with Compressor and Turbine Casing
122
Fig. 73: Installing the Gas Outlet Flange
123
Installing the Gas Outlet Flange
123
Fig. 74: Measuring Clearances N and R
124
Radial Clearances N and R
124
Table 51: Permissible Clearances N and R
124
Fig. 75: Fitting the Insulation
125
Fitting the Insulation
125
Fig. 76: Installing the Cartridge Group with Compressor and Turbine Casing
126
Fig. 77: Installing the Cartridge Group with Compressor and Turbine Casing
126
Installing the Cartridge Group with Compressor and Turbine Casing
126
Fig. 78: Fitting Gas Outlet Casing Without Support
127
Installing the Gas Outlet Casing
127
Table 52: Tightening Torque (51009)
127
Fig. 79: Installing Gas Outlet Casing with Support 1
128
Table 53: Tightening Torque (51009)
128
Fig. 80: Installing Gas Outlet Casing with Support 2
129
Fig. 81: Installing the Air Inlets
130
Installing Air Inlets
130
Table 54: Tightening Torque (72051)
130
Fig. 82: Installing the Uncoupled Filter Silencer
131
Table 55: Tightening Torque (72054)
131
Dismantling and Fitting, Cartridge Concept
132
Fig. 83: Removing the Air Inlets
132
Removing Air Inlets
132
Fig. 84: Removing the Uncoupled Filter Silencer
133
Fig. 85: Removing the Compressor Casing
134
Removing the Compressor Casing
134
Fig. 86: Pressing off Compressor Casing
135
Fig. 87: Remove the Diffuser
135
Fig. 88: Dismantling the Diffuser and the Wall Insert
136
Fig. 89: Removing Insulation Sheets
137
Fig. 90: Removing Cartridge Group 1
137
Removing the Cartridge Group
137
Table 56: Threaded Rod, Value X
137
1. Treat Threads of Studs (51006) with Penetrating Oil and Leave to Take Effect
138
Fig. 91: Removing Cartridge Group 2
138
Fig. 92: Removing Cartridge Group 2
139
Fig. 93: S_05180
140
Removing the Nozzle Ring
140
Fig. 94: Measuring Clearance a and B
141
Measuring Clearance a and B
141
Table 57: Permissible Clearances a and B
141
Fig. 95: Nozzle Ring Compression PD
142
Nozzle Ring Compression PD
142
Table 58: Nozzle Ring Compression PD
142
Fig. 96: Installing the Nozzle Ring
143
Installing Nozzle Ring
143
Fig. 97: Installing the Cartridge Group 1
144
Installing the Cartridge Group
144
Fig. 98: Installing the Cartridge Group 2
145
Table 59: Threaded Rod, Value X and L
145
Table 60: Tightening Torque (51007)
145
Tightening Torque
145
Fig. 99: Fitting the Wall Insert and the Diffuser
146
Installing the Compressor Casing
146
Table 61: Tightening Torque (79041)
146
Fig. 100: Installing the Compressor Casing
147
Table 62: Tightening Torque (72011)
147
Fig. 101: Measuring Clearances N and R
148
Radial Clearances N and R
148
Table 63: Permissible Clearances N and R
148
Fig. 102: Fitting the Insulation
149
Fitting the Insulation
149
Fig. 103: Installing the Air Inlets
150
Installing Air Inlets
150
Table 64: Tightening Torque (72051)
150
Fig. 104: Installing the Uncoupled Filter Silencer
151
Table 65: Tightening Torque (72054)
151
Dismantling and Fitting, Special Tools for Fastening Strips
152
Fig. 105: Customer Tool
152
Fig. 106: Customer Tool
152
Table 66: Customer Tool
152
Table 67: Customer Tool
152
Application, Special Tools
153
Fig. 107: Positioning the Collection Tub
153
Fig. 108: Removing the Fastening Strips
153
Fig. 109: Fitting the Upper Fastening Strips
154
Fig. 110: Fitting the Bottom Fastening Strip
154
Table 68: Tightening Torque (51007)
154
Fig. 111: Fitting the Bottom Fastening Strip
155
Table 69: Tightening Torque (51007) with Spanner Holder
155
Fig. 112: Fitting the Cartridge Group
156
Table 70: Tightening Torque (51007)
156
Fig. 113: Positioning the Fastening Strip
157
Fig. 114: Clamping Piece
158
Fig. 115: Attach Nut
159
Table 71: Tightening Torque (51007) with Spanner Holder
159
Disassembly
160
Fig. 116: Initial Situation
160
Fig. 117: Disassembly of the Elbows
160
Removing and Installing 6-Nozzle Turbine Cleaning Component (Optional)
160
Fig. 118: Disassembly of the Elbows
161
Fig. 119: Pipe Disassembly
161
Fig. 120: Disassembly of the Connecting Pieces
162
Fig. 121: Disassembly of the Cleaning Nozzle
162
Table 72: Dismantling Screw
162
Assembly
163
Fig. 122: Assembly of the Cleaning Nozzle
163
Fig. 123: Assembly of the Connecting Pieces
163
Table 73: Dismantling Screw
163
Fig. 124: Pipe Assembly
164
Fig. 125: Elbow 1 Assembly
164
Fig. 126: Elbow 2 Assembly
165
Table 74: Tightening Torque (51314 / 51316)
165
Fig. 127: Fit the Cleaning Nozzles
166
Fitting the Cleaning Nozzles with Multi-Inlet Turbine Casings
166
Possible Emergency Repairs
167
Taking out of Operation at Short Notice
167
Installing the Replacement Cartridge Group
168
Installing the Replacement Turbocharger
168
Fig. 128: Fitting the Cover Plate
169
Fitting the Cover Plate
169
Cover Plate Drawing
170
Fig. 129: Cover Plate Drawing
170
Table 75: Cover Plate Dimensions [MM]
170
Fig. 130: Dimensions for Cover Plate
171
Table 76: Cover Plate Dimensions [MM]
171
Mothballing the Turbocharger
172
Taking the Engine out of Operation for up to 12 Months
172
Taking the Engine out of Operation for more than 12 Months
173
Disposing of Turbocharger Components
174
Ordering Spare Parts
175
Required Customer Spare Part Set (97070)
175
Spare Parts
175
Table 77: Customer Spare Part Set 97070
175
Spare Part - Illustrations
176
Table 78: Spare Parts - Cartridge, Oil Cooled
177
Table 79: Spare Parts - Bearing, Casing Oil Cooled
178
Table 80: Spare Parts - Rotor and Bearing Parts
179
Table 81: Spare Parts - Turbine Casing, 1 Inlet
180
Table 82: Spare Parts - Turbine Casing, 2 Inlets
181
Table 83: Spare Parts - Turbine Casing, 3 Inlets
182
Table 84: Spare Parts - Cleaning Device
183
Table 85: Spare Parts - Gas Outlet Casing, Radial
184
Table 86: Spare Parts - Compressor Casing
185
Table 87: Spare Parts - Filter Silencer
187
Table 88: Spare Parts - Air Suction Branch Axial
187
Table 89: Spare Parts - Air Suction Branch Radial
188
Table 90: Spare Parts - Speed Measurement System
189
Fig. 131: Special Tool
190
Table 91: Customer Tool Set 90000
190
Table 92: Special Tool (90160)
190
Tools
190
Fig. 132: Special Tool
191
Table 93: Special Tool (90160)
191
Figures
192
Tables
195
4
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ABB A155-M66 Specifications
General
Brand
ABB
Model
A155-M66
Category
Industrial Equipment
Language
English
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