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XAC21390
ABB XAC21390 User Manual
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Operating limits and replacement intervals
The recommended replacement intervals and the corresponding operating limits in
chapter 3
are jointly defined
with the enginebuilder. This information is specific to the product.
Non-observance of the recommended replacement intervals and the operating limits increases the risk of unpre-
dictable component failures.
1
3
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
Warning Plates on the Turbocharger
15
Turbocharger Rating Plate
16
Periodic Check of the Pressure Vessels
17
Lifting of Loads
18
Prerequisites for Operation and Maintenance
19
Hazards During Operation and Maintenance
20
Safe Operation
22
Safe Maintenance
23
Product Description
29
Essential Information
31
Introduction
31
Registered Trademarks
31
Related Documents
31
Table 1: Related Documents
31
Fig. 1: Layout and Function of the Turbocharger
32
Layout and Function of the Turbocharger
32
Fig. 2: Warning Plate Locations
34
Warning Plates on the Turbocharger
34
Fig. 3: Locations of the Rating Plates
35
Locations of the Rating Plates
35
Removal and Installation
36
Removing the Turbocharger
36
Table 2: A100-L Weights
36
Turbocharger Weight
36
Fig. 4: Fitting Lifting Gear to Turbocharger
37
Fig. 5: Placing the Turbocharger on the Bracket
38
Installing the Turbocharger
38
Fig. 6: Compressor-End Foot
39
Fig. 7: Turbine-End Foot
39
Table 3: General Information about Fastening the Turbocharger
39
Table 4: Tightening Torques (Foot Screws)
40
Table 5: Tightening Angle (Foot Screws)
40
Commissioning
41
Inspection Procedures
41
Oil Supply
41
Commissioning after Taking out of Operation
43
Monitoring During Operation
44
Oil Pressure, Oil Temperature
44
Table 6: Lubricating Oil Pressure, Oil Inlet
44
Table 7: Lubricating Oil Temperature at the Inlet
44
Table 8: Lubricating Oil Temperature at the Outlet
45
Admissible Air Inlet Temperature
46
Fig. 8: Layout and Overview of the Speed Measurement System
46
Turbocharger Speed
46
Fig. 9: Replacing the Speed Sensor
48
Table 9: Tightening Torques (86505)
48
Fig. 10: U-Tube Manometer at the Filter Silencer
49
Low Pressure Measurement at the Filter Silencer
49
Noise Emission
50
Operation and Service
50
Fig. 11: Noise Insulation, Bellows
51
Service Work
51
Expected Replacement Intervals
55
Table 10: Expected Replacement Intervals for Turbocharger Parts
55
Table 11: Recommended Replacement Intervals for Turbocharger Parts
55
Flexible Turbocharger Cut-Out
56
Stopping the Engine
57
Foreword to Maintenance
58
Periodic Maintenance
58
Cleaning the Filter Silencer
59
Fig. 12: Layout and Overview of Filter Silencer
59
Changing the Filter Strip on the Filter Silencer Casing
61
Fig. 13: Dismantling Filter Ring Circumferential Part
61
Fig. 14: Opening Filter Ring Lock
61
Fig. 15: Attaching New Filter Ring
62
Fig. 16: Fitting New Filter Ring
62
Cleaning the Compressor During Operation
63
Fig. 17: Overview of Wet Cleaning of Compressor
65
Fig. 18: Filter Plug View
66
Table 12: Volume of Water Per Cleaning Process
66
Table 13: Tightening Torques (81125)
66
Cleaning the Turbine During Operation
67
Fig. 19: Overview of Dry Cleaning Device
68
Table 14: Amount of Granulate
70
Draining the Gas Outlet Casing
71
Fig. 20: Drain Pipe Diagram
71
Malfunctions When Starting
72
Table 15: Malfunctions When Starting - Delayed Start-Up
72
Table 16: Malfunctions When Starting - Vibrations
72
Table 17: Malfunctions When Starting - Rubbing of Rotating Parts
72
Troubleshooting
72
Malfunctions During Operation
73
Table 18: Malfunctions During Operation - Lubricating Oil Pressure too Low
73
Table 19: Malfunctions During Operation - Drop in Speed
73
Table 20: Malfunctions During Operation - Exhaust Gas Temperature too High
74
Table 21: Malfunctions During Operation - Charge Air Pressure too Low
74
Surging of the Turbocharger
75
Table 22: Malfunctions During Operation - Charge Air Pressure too High
75
Table 23: Surging of the Turbocharger
75
Malfunctions When Stopping
76
Table 24: Malfunctions When Stopping - Runout Noises
76
Table 25: Malfunctions When Stopping - Shortened Runout Time
76
Speed Measurement System
77
Table 26: Malfunctions of the Speed Measurement System
77
Disassembly and Assembly
78
Introduction
78
Fig. 21: Overview of Assembly Weights
80
Table 27: Weights of Assemblies [Kg]
80
Table 28: Weight of Wall Insert [Kg]
80
Weights of Assemblies
80
Disassembly and Assembly of the Filter Silencer Casing
81
Fig. 22: Overview of Filter Silencer Casing Disassembly and Assembly
81
Fig. 23: Fitting Filter Silencer Casing 1
82
Fig. 24: Fitting Filter Silencer Casing 2
83
Fig. 25: Fitting Filter Silencer Casing 3
83
Fig. 26: Fitting Filter Silencer Casing 4
84
Fig. 27: Fitting Filter Silencer Casing 5
84
Fig. 28: Fitting the Bellows
85
Table 29: Tightening Torques (Filter Silencer Screws)
85
Dismantling the Filter Silencer
86
Fig. 29: Dismantling the Filter Silencer
86
Fig. 30: Dismantling the Filter Silencer
87
Dismantling the Filter Silencer with Noise Package
88
Fig. 31: Dismantling the Filter Silencer with Noise Package
88
Dismantling Wall Insert and Diffuser
89
Fig. 32: Pressing off Compressor Casing
89
Fig. 33: Moving out Wall Insert
90
Fig. 34: Putting down Wall Insert
90
Fig. 35: Putting down Wall Insert
91
Fig. 36: Dismantling the Diffuser
92
Axial Clearance a Prior to Disassembly
93
Fig. 37: Measuring Axial Clearance a
93
Table 30: Admissible Axial Clearance a
93
Dismantling the Insulation, the Gas Inlet Casing and the Nozzle Ring (A175-L and Smaller)
94
Fig. 38: Removing the Insulation (A175-L and Smaller)
94
Fig. 39: Dismantling the Gas Inlet Casing (A175-L and Smaller) - Screwed Variant
95
Fig. 40: Dismantling the Gas Inlet Casing (175-L and Smaller) - Threaded Stud Variant
96
Table 31: Maximum Admissible Loosening Torque (51087)
96
Fig. 41: Dismantling the Nozzle Ring (A175-L and Smaller)
97
Dismantling the Gas Inlet Casing, Nozzle Ring (A180-L and Larger)
98
Fig. 42: Dismantling the Gas Inlet Casing (A180-L and Larger) - Screwed Variant
98
Fig. 43: Dismantling the Gas Inlet Casing (180-L and Larger) - Threaded Stud Variant
99
Table 32: Maximum Admissible Loosening Torque (51087)
99
Fig. 44: Fitting the Nozzle Ring Holder
100
Fig. 45: Dismantling the Nozzle Ring (A180-L and Larger)
101
Fig. 46: Putting down the Nozzle Ring (A180-L and Larger)
101
Fig. 47: Fitting the Nozzle Ring (A175-L and Smaller)
102
Fitting the Gas Inlet Casing, the Nozzle Ring and the Insulation (A175-L and Smaller)
102
Table 33: Tightening Torque (56014)
102
Fig. 48: Fitting the Gas Inlet Casing (A175-L and Smaller) - Screwed Variant
103
Table 34: Tightening Torque (61009)
103
Fig. 49: Fitting the Gas Inlet Casing (A175-L and Smaller) - Threaded Stud Variant
104
Table 35: Tightening Torque (51087)
104
Fig. 50: Fit Insulation
105
Fig. 51: Looping Around the Nozzle Ring (A180-L and Larger)
106
Fitting the Gas Inlet Casing, Nozzle Ring (A180-L and Larger)
106
Fig. 52: Fitting the Nozzle Ring (2) (A180-L and Larger)
107
Table 36: Tightening Torque (56014)
107
Fig. 53: Fitting the Gas Inlet Casing (A180-L and Larger) - Screwed Variant
108
Table 37: Tightening Torque (61009)
108
Fig. 54: Fitting the Gas Inlet Casing (A180-L and Larger) - Threaded Stud Variant
109
Table 38: Tightening Torque (51087)
109
Axial Clearance a after Assembly
110
Fig. 55: Measuring Axial Clearance a
110
Table 39: Admissible Axial Clearance a
110
Fig. 56: Fitting the Diffuser
111
Fitting Diffuser, Wall Insert
111
Table 40: Tightening Torque (77015)
111
Fig. 57: Positioning Wall Insert
112
Fig. 58: Fitting the Wall Insert
113
Table 41: Tightening Torque (72011)
113
Fig. 59: Fitting the Filter Silencer
114
Fitting the Filter Silencer
114
Table 42: Tightening Torque (72004)
114
Fig. 60: Fitting the Filter Silencer
115
Table 43: Tightening Torque (72004)
115
Fig. 61: Fitting the Filter Silencer with Noise Package
116
Fitting the Filter Silencer with Noise Package
116
Table 44: Tightening Torques (72004, 74043)
116
Fig. 63: Overview of Speed Sensor Tightening Torque
118
Table of Tightening Torques
118
Fig. 62: Overview of Tightening Torques
119
Table 45: Overview of Tightening Torques
119
Table 46: Tightening Torque, Insulation
119
Possible Emergency Repairs
120
Taking a Turbocharger out of Operation
120
Table 47: Bypass Procedure
121
Taking Defective Turbochargers out of Operation
121
Fig. 64: Locking the Rotor
122
Table 48: Tightening Torque
123
Fig. 65: Ensuring Clamping of the Cover Ring
124
Table 49: Required Washers (01)
124
Table 50: Tightening Torque (57005)
124
Fig. 66: Position of Cover Plates
125
Mothballing the Turbocharger
126
Taking the Engine out of Operation for up to 12 Months
126
Taking the Engine out of Operation for more than 12 Months
127
Disposing of Turbocharger Components
128
Ordering Spare Parts
129
Spare Parts
129
Table 51: Customer Spare Part Set (97070)
129
Table 52: Customer Spare Part Set (97071)
130
Fig. 67: View of Turbocharger with Part Numbers
132
View of Turbocharger with Part Numbers
132
Table 53: Turbocharger with Part Numbers
133
Fig. 68: View of Cartridge Group with Part Numbers
134
View of Cartridge Group with Part Numbers
134
Table 54: Cartridge Group with Part Numbers
135
Figures
136
4
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ABB XAC21390 Specifications
General
Brand
ABB
Model
XAC21390
Category
Industrial Equipment
Language
English
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