ABB A275-L59 - Page 124

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Operation Manual / 4 Product description / A200-L

9 Taking a turbocharger out of operation / 9.2 Taking defective tur-

bochargers out of operation

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Table of Contents3
Introduction4
Purpose of the Manual4
Symbols, Definitions5
Storage of New Turbochargers and Spare Parts7
Contact Information9
Safety12
Introduction12
CE Conformity12
Definition of Mandatory Signs13
Definition of Safety Instructions13
Intended Use14
Warning Plates on the Turbocharger15
Turbocharger Rating Plate16
Periodic Check of the Pressure Vessels17
Lifting of Loads18
Prerequisites for Operation and Maintenance19
Hazards During Operation and Maintenance20
Safe Operation22
Safe Maintenance23
Introduction31
Essential Information31
Registered Trademarks31
Related Documents31
Table 1: Related Documents31
Layout and Function of the Turbocharger32
Fig. 1: Layout and Function of the Turbocharger32
Warning Plates on the Turbocharger34
Fig. 2: Warning Plate Locations34
Locations of the Rating Plates35
Fig. 3: Locations of the Rating Plates35
Removal and Installation36
Turbocharger Weight36
Removing the Turbocharger36
Table 2: Weights A200-L with Filter Silencer36
Fig. 4: Fitting Lifting Gear to Turbocharger37
Installing the Turbocharger38
Fig. 5: Placing the Turbocharger on the Bracket38
Fig. 6: Compressor-End Foot39
Fig. 7: Turbine-End Foot39
Table 3: General Information about Fastening the Turbocharger39
Table 4: Tightening Torques (Foot Screws)40
Table 5: Tightening Angle (Foot Screws)40
Commissioning41
Oil Supply41
Inspection Procedures41
Commissioning after Taking out of Operation43
Monitoring During Operation44
Oil Pressure, Oil Temperature44
Table 6: Lubricating Oil Pressure, Oil Inlet44
Table 7: Lubricating Oil Temperature at the Inlet44
Table 8: Lubricating Oil Temperature at the Outlet45
Admissible Air Inlet Temperature46
Turbocharger Speed46
Fig. 8: Layout and Overview of the Speed Measurement System46
Fig. 9: Replacing the Speed Sensor48
Table 9: Tightening Torques (86505)48
Low Pressure Measurement at the Filter Silencer49
Fig. 10: U-Tube Manometer at the Filter Silencer49
Operation and Service50
Noise Emission50
Service Work51
Fig. 11: Noise Insulation, Bellows51
Expected Replacement Intervals55
Table 10: Expected Replacement Intervals for Turbocharger Parts55
Table 11: Recommended Replacement Intervals for Turbocharger Parts55
Flexible Turbocharger Cut-Out56
Stopping the Engine57
Periodic Maintenance58
Foreword to Maintenance58
Cleaning the Filter Silencer59
Fig. 12: Layout and Overview of Filter Silencer59
Changing the Filter Strip on the Filter Silencer Casing61
Fig. 13: Dismantling Filter Ring Circumferential Part61
Fig. 14: Opening Filter Ring Lock61
Fig. 15: Attaching New Filter Ring62
Fig. 16: Fitting New Filter Ring62
Cleaning the Compressor During Operation63
Fig. 17: Overview of Wet Cleaning of Compressor65
Fig. 18: Filter Plug View66
Table 12: Volume of Water Per Cleaning Process66
Table 13: Tightening Torques (81125)66
Cleaning the Turbine During Operation67
Fig. 19: Overview of Dry Cleaning Device68
Table 14: Cleaning Parameters70
Draining the Gas Outlet Casing71
Fig. 20: Drain Pipe Diagram71
Troubleshooting72
Malfunctions When Starting72
Table 15: Malfunctions When Starting - Delayed Start-Up72
Table 16: Malfunctions When Starting - Vibrations72
Table 17: Malfunctions When Starting - Rubbing of Rotating Parts72
Malfunctions During Operation73
Table 18: Malfunctions During Operation - Lubricating Oil Pressure too Low73
Table 19: Malfunctions During Operation - Drop in Speed73
Table 20: Malfunctions During Operation - Exhaust Gas Temperature too High74
Table 21: Malfunctions During Operation - Charge Air Pressure too Low74
Surging of the Turbocharger75
Table 22: Malfunctions During Operation - Charge Air Pressure too High75
Table 23: Surging of the Turbocharger75
Malfunctions When Stopping76
Table 24: Malfunctions When Stopping - Runout Noises76
Table 25: Malfunctions When Stopping - Shortened Runout Time76
Speed Measurement System77
Table 26: Malfunctions of the Speed Measurement System77
Disassembly and Assembly78
Introduction78
Weights of Assemblies80
Fig. 21: Overview of Assembly Weights80
Table 27: Weights of Assemblies [Kg]80
Table 28: Weight of Wall Insert [Kg]80
Disassembly and Assembly of the Filter Silencer Casing81
Fig. 22: Overview of Filter Silencer Casing Disassembly and Assembly81
Fig. 23: Fitting Filter Silencer Casing 182
Fig. 24: Fitting Filter Silencer Casing 283
Fig. 25: Fitting Filter Silencer Casing 383
Fig. 26: Fitting Filter Silencer Casing 484
Fig. 27: Fitting Filter Silencer Casing 584
Fig. 28: Fitting the Bellows85
Table 29: Tightening Torques (Filter Silencer Screws)85
Dismantling the Filter Silencer86
Fig. 29: Dismantling the Filter Silencer86
Fig. 30: Dismantling the Filter Silencer87
Dismantling Wall Insert and Diffuser88
Fig. 31: Pressing off Compressor Casing88
Fig. 32: Moving out Wall Insert89
Fig. 33: Putting down Wall Insert89
Fig. 34: Putting down Wall Insert90
Fig. 35: Dismantling the Diffuser91
Axial Clearance a Prior to Disassembly92
Fig. 36: Measuring Axial Clearance a92
Table 30: Admissible Axial Clearance a92
Dismantling the Insulation, the Gas Inlet Casing and the Nozzle Ring (A275-L and Smaller)93
Fig. 37: Removing the Insulation (A275-L and Smaller)93
Fig. 38: Dismantling the Gas Inlet Casing (A275-L and Smaller) - Screwed Variant94
Fig. 39: Dismantling the Gas Inlet Casing (275-L and Smaller) - Threaded Stud Variant95
Table 31: Maximum Admissible Loosening Torque (51087)95
Fig. 40: Dismantling the Nozzle Ring (A275-L and Smaller)96
Dismantling the Gas Inlet Casing, Nozzle Ring (A280-L)97
Fig. 41: Dismantling the Gas Inlet Casing (A280-L) - Screwed Variant97
Fig. 42: Dismantling the Gas Inlet Casing (A280-L) - Threaded Stud Variant98
Table 32: Maximum Admissible Loosening Torque (51087)98
Fig. 43: Fitting the Nozzle Ring Holder (A280-L)99
Fig. 44: Dismantling the Nozzle Ring (A280-L)100
Fig. 45: Putting down the Nozzle Ring (A280-L)100
Fitting Gas Inlet Casing, Nozzle Ring, Insulation (A275-L and Smaller)101
Fig. 46: Fitting the Nozzle Ring (A275-L and Smaller)101
Table 33: Tightening Torque (56014)101
Fig. 47: Fitting the Gas Inlet Casing (A275-L and Smaller) - Screwed Variant102
Table 34: Tightening Torque (61009)102
Fig. 48: Fitting the Gas Inlet Casing (A275-L and Smaller) - Threaded Stud Variant103
Table 35: Tightening Torque (51087)103
Fig. 49: Fitting the Insulation (A275-L and Smaller)104
Fitting the Gas Inlet Casing, Nozzle Ring (A280-L)105
Fig. 50: Fitting the Nozzle Ring (A280-L)105
Fig. 51: Attaching the Nozzle Ring (A280-L)106
Table 36: Tightening Torque (56014)106
Fig. 52: Fitting the Gas Inlet Casing (A280-L) - Screwed Variant107
Table 37: Tightening Torque (61009)107
Fig. 53: Fitting the Gas Inlet Casing (A280-L) - Screwed Variant108
Table 38: Tightening Torque (51087)108
Axial Clearance a after Assembly109
Fig. 54: Measuring Axial Clearance a109
Table 39: Admissible Axial Clearance a109
Fitting Diffuser, Wall Insert110
Fig. 55: Fitting the Diffuser110
Table 40: Tightening Torque (77015)110
Fig. 56: Positioning Wall Insert111
Fig. 57: Fitting the Wall Insert112
Table 41: Tightening Torque (72011)112
Fitting the Filter Silencer113
Fig. 58: Fitting the Filter Silencer113
Table 42: Tightening Torque (72004)113
Fig. 59: Fitting the Filter Silencer114
Table 43: Tightening Torque (72004)114
Table of Tightening Torques116
Fig. 60: Overview of Tightening Torques116
Fig. 61: Overview of Speed Sensor Tightening Torque116
Table 44: Overview of Tightening Torques117
Table 45: Tightening Torque, Insulation117
Taking a Turbocharger out of Operation118
Possible Emergency Repairs118
Taking Defective Turbochargers out of Operation119
Table 46: Bypass Procedure119
Fig. 62: Locking the Rotor120
Table 47: Tightening Torque B121
Fig. 63: Ensuring Clamping of the Cover Ring122
Table 48: Required Washers (01)122
Table 49: Tightening Torque (57005)122
Fig. 64: Position of Cover Plates123
Mothballing the Turbocharger125
Taking the Engine out of Operation for up to 12 Months125
Taking the Engine out of Operation for more than 12 Months126
Disposing of Turbocharger Components127
Spare Parts128
Ordering Spare Parts128
Table 50: Customer Spare Part Set (97070)128
Table 51: Customer Spare Part Set (97071)129
View of Turbocharger with Part Numbers130
Fig. 65: View of Turbocharger with Part Numbers130
Table 52: Turbocharger with Part Numbers131
View of Cartridge Group with Part Numbers132
Fig. 66: View of Cartridge Group with Part Numbers132
Table 53: Cartridge Group with Part Numbers133
Figures134

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