ABB XAC22682 - Installing the Turbocharger; Fig. 5: Placing the Turbocharger

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Operation Manual / 4 Product description / A200-L

2 Removal and installation / 2.3 Installing the turbocharger

2.3 Installing the turbocharger

2.3.1 Placing the turbocharger on the bracket

Fig.5: Placing the turbocharger

u Remove covers from the oil connections.

u Align turbocharger and place on engine bracket.

u Tighten the fixing screws (Steps for fastening the turbocharger →11) while only slightly

loosening the lifting gear.

u Remove lifting gear from turbocharger.

u Connect cable to speed sensor.

u Connect all gas, air and oil pipes.

Page 10 / 110

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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
Deflagration on Gas Engines15
Warning Plates on the Turbocharger16
Turbocharger Rating Plate17
Periodic Check of the Pressure Vessels18
Lifting of Loads19
Prerequisites for Operation and Maintenance20
Hazards During Operation and Maintenance21
Safe Operation23
Safe Maintenance24
Introduction33
Essential Information33
Registered Trademarks33
Related Documents33
Table 1: Related Documents33
Layout and Function of the Turbocharger34
Fig. 1: Layout and Function of the Turbocharger34
Warning Plates on the Turbocharger36
Fig. 2: Warning Plate Locations36
Locations of the Rating Plates37
Fig. 3: Locations of the Rating Plates37
Removal and Installation38
Turbocharger Weight38
Removing the Turbocharger38
Table 2: Total Weight38
Fig. 4: Fitting the Lifting Gear39
Installing the Turbocharger40
Fig. 5: Placing the Turbocharger40
Fig. 6: Compressor-End Foot41
Fig. 7: Turbine-End Foot41
Table 3: General Information about Fastening the Turbocharger41
Table 4: Tightening Torques (Foot Screws)42
Table 5: Tightening Angle (Foot Screws)42
Commissioning43
Oil Supply43
Inspection Procedures43
Commissioning after Taking out of Operation45
Monitoring During Operation46
Oil Pressure, Oil Temperature46
Table 6: Lubricating Oil Pressure, Oil Inlet46
Fig. 8: Oil Temperature at the Outlet47
Table 7: Lubricating Oil Temperature at the Inlet47
Table 8: Lubricating Oil Temperature at the Outlet47
Admissible Air Inlet Temperature49
Turbocharger Speed49
Fig. 9: Layout and Overview of the Speed Measurement System49
Fig. 10: Replacing the Speed Sensor51
Table 9: Tightening Torques (86505)51
Low Pressure Measurement at the Filter Silencer52
Fig. 11: U-Tube Manometer at the Filter Silencer52
Operation and Service53
Noise Emission53
Service Work54
Fig. 12: Noise Insulation, Bellows54
Expected Replacement Intervals58
Table 10: Expected Replacement Intervals for Turbocharger Parts58
Table 11: Recommended Replacement Intervals for Turbocharger Parts58
Flexible Turbocharger Cut-Out59
Stopping the Engine60
Periodic Maintenance61
Foreword to Maintenance61
Cleaning the Filter Silencer62
Fig. 13: Layout and Overview of Filter Silencer62
Changing the Filter Strip on the Filter Silencer Casing64
Fig. 14: Dismantling Filter Ring Circumferential Part64
Fig. 15: Opening Filter Ring Lock64
Fig. 16: Attaching New Filter Ring65
Fig. 17: Fitting New Filter Ring65
Cleaning the Compressor During Operation66
Fig. 18: Overview of Wet Cleaning of Compressor68
Fig. 19: Filter Plug View69
Table 12: Volume of Water Per Cleaning Process69
Table 13: Tightening Torques (81125)69
Cleaning the Turbine During Operation70
Fig. 20: Overview of Dry Cleaning Device71
Table 14: Cleaning Parameters73
Draining the Gas Outlet Casing74
Fig. 21: Drain Pipe Diagram74
Troubleshooting75
Malfunctions When Starting75
Table 15: Malfunctions When Starting - Delayed Start-Up75
Table 16: Malfunctions When Starting - Vibrations75
Table 17: Malfunctions When Starting - Rubbing of Rotating Parts75
Malfunctions During Operation76
Table 18: Malfunctions During Operation - Lubricating Oil Pressure too Low76
Table 19: Malfunctions During Operation - Drop in Speed76
Table 20: Malfunctions During Operation - Exhaust Gas Temperature too High77
Table 21: Malfunctions During Operation - Charge Air Pressure too Low77
Surging of the Turbocharger78
Table 22: Malfunctions During Operation - Charge Air Pressure too High78
Table 23: Surging of the Turbocharger78
Malfunctions When Stopping79
Table 24: Malfunctions When Stopping - Runout Noises79
Table 25: Malfunctions When Stopping - Shortened Runout Time79
Speed Measurement System80
Table 26: Malfunctions of the Speed Measurement System80
Disassembly and Assembly82
Introduction82
Weights of Assemblies84
Fig. 22: Weights of Assemblies84
Table 27: Weights of Assemblies [Kg]84
Table 28: Weight of Wall Insert [Kg]84
Disassembly and Assembly of the Filter Silencer Casing85
Fig. 23: Dismantling the Filter Silencer Casing85
Fig. 24: Fitting the Filter Silencer Casing86
Fig. 25: Fitting the Filter Silencer Casing87
Fig. 26: Fitting the Filter Silencer Casing87
Fig. 27: Fitting the Filter Silencer Casing88
Fig. 28: Fitting the Filter Silencer Casing88
Fig. 29: Fitting the Bellows89
Table 29: Tightening Torques (Filter Silencer Screws)89
Dismantling the Filter Silencer90
Fig. 30: Dismantling the Filter Silencer90
Fig. 31: Dismantling the Filter Silencer91
Dismantling Wall Insert and Diffuser92
Fig. 33: Moving out Wall Insert93
Fig. 34: Putting down Wall Insert93
Fig. 36: Moving out Wall Insert95
Fig. 37: Putting down Wall Insert95
Fig. 38: Putting down Wall Insert96
Fig. 39: Dismantling the Diffuser97
Axial Clearance a Prior to Disassembly98
Fig. 40: Measuring Axial Clearance a98
Table 30: Axial Clearance a98
Dismantling the Insulation (≤ A275-L)99
Fig. 41: Removing the Insulation (A275-L and Smaller)99
Dismantling the Gas Inlet Casing (≤ A275-L)100
Fig. 42: Dismantling the Gas Inlet Casing (275-L and Smaller)100
Table 31: Maximum Admissible Loosening Torque (51087)100
Dismantling the Nozzle Ring (≤ A275-L)101
Fig. 43: Dismantling the Nozzle Ring (A275-L and Smaller)101
Dismantling the Gas Inlet Casing (A280-L)102
Fig. 44: Dismantling the Gas Inlet Casing (A280-L)102
Table 32: Maximum Admissible Loosening Torque (51087)102
Dismantling the Nozzle Ring (A280-L)103
Fig. 45: Fitting the Nozzle Ring Holder103
Fig. 46: Dismantling the Nozzle Ring104
Fig. 47: Put down the Nozzle Ring104
Fitting the Nozzle Ring (≤ A275-L)105
Fig. 48: Fitting the Nozzle Ring (A275-L and Smaller)105
Table 33: Tightening Torque (56014)105
Fitting the Gas Inlet Casing (≤ A275-L)106
Fig. 49: Fitting the Gas Outlet Casing (A275-L and Smaller)106
Table 34: Tightening Torque (51087)106
Fitting the Insulation (≤ A275-L)107
Fig. 50: Fitting the Insulation (A275-L and Smaller)107
Fitting the Nozzle Ring (A280-L)108
Fig. 51: Fitting the Nozzle Ring (A280-L)108
Fig. 52: Attaching the Nozzle Ring (A280-L)109
Table 35: Tightening Torque (56014)109
Fitting the Gas Inlet Casing (A280-L)110
Fig. 53: Fitting the Gas Inlet Casing (A280-L)110
Table 36: Tightening Torque (51087)110
Axial Clearance a after Assembly111
Fig. 54: Measuring Axial Clearance a111
Table 37: Axial Clearance a111
Fitting the Diffuser112
Fig. 55: Fitting the Diffuser112
Table 38: Tightening Torque (77015)112
Fitting Wall Insert113
Fig. 56: Positioning Wall Insert113
Fig. 57: Fitting the Wall Insert (A255-L114
Table 39: Tightening Torque (72002)114
Table 40: Tightening Torque (72004)114
Fig. 58: Fitting the Wall Insert (A265-L116
Table 41: Tightening Torque (72011)116
Fitting the Filter Silencer117
Fig. 59: Fitting the Filter Silencer118
Table 42: Tightening Torque (72004)118
Fig. 60: Fitting the Filter Silencer119
Table 43: Tightening Torque (72004)119
Table of Tightening Torques120
Fig. 62: Overview of Speed Sensor Tightening Torque120
Fig. 61: Overview of Tightening Torques121
Table 44: Overview of Tightening Torques121
Table 45: Tightening Torque, Insulation121
Taking a Turbocharger out of Operation122
Possible Emergency Repairs122
Taking Defective Turbochargers out of Operation123
Table 46: Bypass Procedure123
Fig. 63: Locking the Rotor124
Table 47: Tightening Torque B125
Fig. 64: Ensuring Clamping of the Cover Ring126
Table 48: Required Washers (01)126
Table 49: Tightening Torque (57005)126
Fig. 65: Position of Cover Plates127
Mothballing the Turbocharger129
Taking the Engine out of Operation for up to 12 Months129
Taking the Engine out of Operation for more than 12 Months130
Disposing of Turbocharger Components131
Spare Parts132
Ordering Spare Parts132
Table 50: Customer Spare Part Set (97070)132
Table 51: Customer Spare Part Set (97071)133
View of Turbocharger with Part Numbers134
Fig. 66: View of Turbocharger with Part Numbers134
Table 52: Turbocharger with Part Numbers135
View of Cartridge Group with Part Numbers136
Fig. 67: View of Cartridge Group with Part Numbers136
Table 53: Cartridge Group with Part Numbers137
Figures138

ABB XAC22682 - Installing the Turbocharger; Fig. 5: Placing the Turbocharger

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