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XAC22451
ABB XAC22451 User Manual
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Operation Manual / 4 Product description / A200-L
8 Disassembly and assembly / 8.5 Dismantling wall insert and diffuser
© Copyright 2018 ABB. All rights reserved.
HZTL4036_EN
Revision M
August 2018
Fig.35: Dismantling the diffuser
4.
Loosen and remove screws(77015).
5.
Remove O-rings(79020, 79021).
6.
Attach lifting gear (L) to the diffuser(79000).
7.
Remove and put down diffuser.
Page 63 / 108
90
92
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: Weights A200-L with Filter Silencer
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: Cleaning Parameters
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 Wall Insert and Diffuser
88
Fig. 31: Pressing off Compressor Casing
88
Fig. 32: Moving out Wall Insert
89
Fig. 33: Putting down Wall Insert
89
Fig. 34: Putting down Wall Insert
90
Fig. 35: Dismantling the Diffuser
91
Axial Clearance a Prior to Disassembly
92
Fig. 36: Measuring Axial Clearance a
92
Table 30: Admissible Axial Clearance a
92
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 Variant
94
Fig. 39: Dismantling the Gas Inlet Casing (275-L and Smaller) - Threaded Stud Variant
95
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 Variant
97
Fig. 42: Dismantling the Gas Inlet Casing (A280-L) - Threaded Stud Variant
98
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
Fig. 46: Fitting the Nozzle Ring (A275-L and Smaller)
101
Fitting Gas Inlet Casing, Nozzle Ring, Insulation (A275-L and Smaller)
101
Table 33: Tightening Torque (56014)
101
Fig. 47: Fitting the Gas Inlet Casing (A275-L and Smaller) - Screwed Variant
102
Table 34: Tightening Torque (61009)
102
Fig. 48: Fitting the Gas Inlet Casing (A275-L and Smaller) - Threaded Stud Variant
103
Table 35: Tightening Torque (51087)
103
Fig. 49: Fitting the Insulation (A275-L and Smaller)
104
Fig. 50: Fitting the Nozzle Ring (A280-L)
105
Fitting the Gas Inlet Casing, 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 Variant
107
Table 37: Tightening Torque (61009)
107
Fig. 53: Fitting the Gas Inlet Casing (A280-L) - Screwed Variant
108
Table 38: Tightening Torque (51087)
108
Axial Clearance a after Assembly
109
Fig. 54: Measuring Axial Clearance a
109
Table 39: Admissible Axial Clearance a
109
Fig. 55: Fitting the Diffuser
110
Fitting Diffuser, Wall Insert
110
Table 40: Tightening Torque (77015)
110
Fig. 56: Positioning Wall Insert
111
Fig. 57: Fitting the Wall Insert
112
Table 41: Tightening Torque (72011)
112
Fig. 58: Fitting the Filter Silencer
113
Fitting the Filter Silencer
113
Table 42: Tightening Torque (72004)
113
Fig. 59: Fitting the Filter Silencer
114
Table 43: Tightening Torque (72004)
114
Fig. 60: Overview of Tightening Torques
116
Fig. 61: Overview of Speed Sensor Tightening Torque
116
Table of Tightening Torques
116
Table 44: Overview of Tightening Torques
117
Table 45: Tightening Torque, Insulation
117
Possible Emergency Repairs
118
Shutting off Oil Supply to Defective Turbocharger
118
Table 46: Procedure for Taking out of Operation
118
Taking a Turbocharger out of Operation
118
Procedure with One Installed Turbocharger
119
Fig. 62: Locking the Rotor
120
Table 47: Tightening Torques (Locking Device)
121
Fig. 63: Ensuring Clamping of the Cover Ring
122
Table 48: Required Washers (01)
122
Table 49: Tightening Torque (57005)
122
Fig. 64: Position of Cover Plates
123
Procedure with Two or more Installed Turbochargers
123
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 50: Customer Spare Part Set (97070)
129
Fig. 65: View of Turbocharger with Part Numbers
130
View of Turbocharger with Part Numbers
130
Table 51: Turbocharger with Part Numbers
131
Fig. 66: View of Cartridge Group with Part Numbers
132
View of Cartridge Group with Part Numbers
132
Table 52: Cartridge Group with Part Numbers
133
Figures
134
4
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ABB XAC22451 Specifications
General
Brand
ABB
Model
XAC22451
Category
Industrial Equipment
Language
English
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