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ABB XAC26457 User Manual
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Operation Manual / A100-L
2 Safety / 2.14 Safe maintenance
© Copyright 2021 ABB. All rights reserved.
HZTL4034_EN
Rev.T
December 2021
CAUTION
Mechanical operations on the turbocharger
Components of the turbocharger can be damaged or destroyed as a result
of improper procedures.
u
Only perform operations that are described in this chapter.
u
Only perform operations for which you have received instruction or train-
ing.
Page 22 / 141
23
25
Table of Contents
Operation Manual / A100-L
3
Table of Contents
3
Introduction
6
Essential Information
7
Registered Trademarks
7
Layout and Function of the Turbocharger
8
Fig. 1: Layout and Function of the Turbocharger
8
Locations of the Rating Plates
10
Fig. 2: Locations of the Rating Plates
10
Safety
11
Introduction
11
CE Conformity
11
Table 2: Personal Protective Equipment to be Worn Specific to the Respective Task
12
Table 1: Personal Protective Equipment to be Worn at All Times
12
Definition of Safety Instructions
12
Definition of Mandatory Signs
12
Intended Use
13
Deflagration on Gas Engines
14
Warning Plates on the Turbocharger
15
Turbocharger Rating Plate
15
Fig. 3: Warning Plate Locations
15
Fig. 4: Rating Plate
15
Periodic Check of the Pressure Vessels
17
Lifting of Loads
18
Fig. 5: Attachment of Loads on the Crane Hook
18
Fig. 6: Attachment Angle
18
Prerequisites for Operation and Maintenance
19
Hazards During Operation and Maintenance
20
Safe Operation
21
Safe Maintenance
22
Turbocharger Weight
27
Removing the Turbocharger
27
Table 3: Total Weight
27
Removal and Installation
27
Fig. 7: Fitting the Lifting Gear
28
Installing the Turbocharger
29
Fig. 8: Placing the Turbocharger
29
Fig. 9: Compressor-End Foot
30
Fig. 10: Turbine-End Foot
30
Table 4: General Information about Fastening the Turbocharger
30
Table 5: Tightening Torques (Foot Screws)
31
Table 6: Tightening Angle (Foot Screws)
31
Inspection Procedures
32
Commissioning
32
Oil Supply
32
Commissioning after Taking out of Operation
34
Monitoring During Operation
35
Oil Pressure, Oil Temperature
35
Table 7: Lubricating Oil Pressure, Oil Inlet
35
Fig. 11: Oil Temperature at the Outlet
36
Table 8: Lubricating Oil Temperature at the Inlet
36
Table 9: Lubricating Oil Temperature at the Outlet
36
Admissible Air Inlet Temperature
38
Turbocharger Speed
38
Fig. 12: Layout and Overview of the Speed Measurement System
38
Table 10: Tightening Torques (86505)
40
Fig. 13: Replacing the Speed Sensor
40
Low Pressure Measurement at the Filter Silencer
41
Fig. 14: U-Tube Manometer at the Filter Silencer
41
Operation and Service
42
Noise Emission
42
Service Work
43
Fig. 15: Noise Insulation, Bellows
43
Expected Replacement Intervals
47
Table 11: Expected Replacement Intervals for Turbocharger Parts
47
Table 12: Recommended Replacement Intervals for Turbocharger Parts
47
Flexible Turbocharger Cut-Out
48
Stopping the Engine
49
Periodic Maintenance
50
Foreword to Maintenance
50
Cleaning the Filter Silencer
51
Fig. 16: Layout and Overview of Filter Silencer
51
Changing the Filter Strip on the Filter Silencer Casing
53
Fig. 17: Dismantling Filter Ring Circumferential Part
53
Fig. 18: Opening Filter Ring Lock
53
Fig. 19: Attaching New Filter Ring
54
Fig. 20: Fitting New Filter Ring
54
Cleaning the Compressor During Operation
55
Fig. 21: Overview of Wet Cleaning of Compressor
57
Fig. 22: Filter Plug View
58
Table 13: Volume of Water Per Cleaning Process
58
Table 14: Tightening Torques (81125)
58
Cleaning the Turbine During Operation
59
Fig. 23: Dry Cleaning Device
60
Table 15: Amount of Granulate
62
Draining the Gas Outlet Casing
63
Fig. 24: Drain Pipe Diagram
63
Troubleshooting
64
Malfunctions When Starting
64
Table 16: Malfunctions When Starting - Delayed Start-Up
64
Table 17: Malfunctions When Starting - Vibrations
64
Table 18: Malfunctions When Starting - Rubbing of Rotating Parts
64
Malfunctions During Operation
65
Table 19: Malfunctions During Operation - Lubricating Oil Pressure too Low
65
Table 20: Malfunctions During Operation - Drop in Speed
65
Table 21: Malfunctions During Operation - Exhaust Gas Temperature too High
66
Table 22: Malfunctions During Operation - Charge Air Pressure too Low
66
Table 24: Surging of the Turbocharger
67
Table 23: Malfunctions During Operation - Charge Air Pressure too High
67
Surging of the Turbocharger
67
Malfunctions When Stopping
68
Table 25: Malfunctions When Stopping - Runout Noises
68
Table 26: Malfunctions When Stopping - Shortened Runout Time
68
Speed Measurement System
69
Table 27: Malfunctions of the Speed Measurement System
69
Disassembly and Assembly
70
Introduction
70
Material Required
71
Weights of Assemblies
72
Fig. 25: Weights of Assemblies
72
Table 28: Weights of Assemblies [Kg]
72
Table 29: Weight of Wall Insert [Kg]
72
Fig. 26: Dismantling the Filter Silencer Casing
73
Disassembly and Assembly of the Filter Silencer Casing
73
Fig. 27: Fitting the Filter Silencer Casing
74
Fig. 28: Fitting the Filter Silencer Casing
75
Fig. 29: Fitting the Filter Silencer Casing
75
Fig. 30: Fitting the Filter Silencer Casing
76
Fig. 31: Fitting the Filter Silencer Casing
76
Fig. 32: Fitting the Bellows
77
Table 30: Tightening Torques (Filter Silencer Screws)
77
Dismantling the Filter Silencer
78
Fig. 33: Dismantling the Filter Silencer
78
Fig. 34: Dismantling the Filter Silencer
79
Dismantling the Filter Silencer with Noise Package
80
Fig. 35: Dismantling the Filter Silencer with Noise Package
80
Dismantling Wall Insert and Diffuser
81
Fig. 36: Dismantling the Wall Insert
81
Fig. 37: Moving out Wall Insert
82
Fig. 38: Putting down Wall Insert
82
Fig. 39: Putting down Wall Insert
83
Fig. 40: Dismantling the Diffuser
84
Axial Clearance a Prior to Disassembly
85
Fig. 41: Measuring Axial Clearance a
85
Table 31: Axial Clearance a
85
Dismantling the Insulation (≤ A175-L)
86
Fig. 42: Removing the Insulation (A175-L and Smaller)
86
Dismantling the Gas Inlet Casing (≤ A175-L)
87
Fig. 43: Dismantling the Gas Inlet Casing (A175-L and Smaller)
87
Table 32: Maximum Admissible Loosening Torque (51087)
87
Dismantling the Nozzle Ring (≤ A175-L)
88
Fig. 44: Dismantling the Nozzle Ring (A175-L and Smaller)
88
Dismantling the Gas Inlet Casing (≥ A180-L)
89
Fig. 45: Dismantling the Gas Inlet Casing (180-L and Larger)
89
Table 33: Maximum Admissible Loosening Torque (51087)
89
Dismantling the Nozzle Ring (≥ A180-L)
90
Fig. 46: Fitting the Nozzle Ring Holder
90
Fig. 47: Dismantling the Nozzle Ring
91
Fig. 48: Put down the Nozzle Ring
91
Fitting the Nozzle Ring (≤ A175-L)
92
Fig. 49: Fitting the Nozzle Ring (A175-L and Smaller)
92
Table 34: Tightening Torque (56014)
92
Table 35: Tightening Torque (51087)
93
Fig. 50: Fitting the Gas Outlet Casing (A175-L and Smaller)
93
Fitting the Gas Inlet Casing (≤ A175-L)
93
Fitting the Insulation (≤ A175-L)
94
Fig. 51: Fitting the Insulation (A175-L and Smaller)
94
Fitting the Nozzle Ring (≥ A180-L)
95
Fig. 52: Looping Around the Nozzle Ring (A180-L and Larger)
95
Fig. 53: Fitting the Nozzle Ring (A180-L and Larger)
96
Table 36: Tightening Torque (56014)
96
Fitting the Gas Inlet Casing (≥ A180-L)
97
Fig. 54: Fitting the Gas Inlet Casing (A180-L and Larger)
97
Table 37: Tightening Torque (51087)
97
Axial Clearance a after Assembly
98
Fig. 55: Measuring Axial Clearance a
98
Table 38: Axial Clearance a
98
Table 39: Tightening Torque (77015)
99
Fig. 56: Fitting the Diffuser
99
Fitting the Diffuser
99
Fitting Wall Insert
100
Fig. 57: Positioning Wall Insert
100
Fig. 58: Fitting Wall Insert
101
Table 40: Tightening Torque (72011)
101
Fitting the Filter Silencer
102
Fig. 59: Fitting the Filter Silencer
103
Table 41: Tightening Torque (72004)
103
Fig. 60: Fitting the Filter Silencer
104
Table 42: Tightening Torque (72004)
104
Fitting the Filter Silencer with Noise Package
105
Fig. 61: Fitting the Filter Silencer with Noise Package
105
Table 43: Tightening Torque (51087)
105
Table of Tightening Torques
107
Fig. 63: Tightening Torques of Speed Sensor
107
Fig. 62: Overview of Tightening Torques
108
Table 44: Overview of Tightening Torques
108
Table 45: Tightening Torque, Insulation
108
Taking a Turbocharger out of Operation
109
Possible Emergency Repairs
109
Taking Defective Turbochargers out of Operation
110
Table 46: Bypass Procedure
110
Fig. 64: Locking the Rotor
111
Table 47: Tightening Torque
111
Fig. 65: Ensuring Clamping of the Cover Ring
113
Table 48: Required Washers (01)
113
Table 49: Tightening Torque (57005)
113
Fig. 66: Position of Cover Plates
114
Mothballing the Turbocharger
115
Taking the Engine out of Operation for up to 12 Months
115
Taking the Engine out of Operation for more than 12 Months
116
Material and Disposal
117
REACH and Rohs Compliance Declaration for Products
117
Disposing of Turbocharger Components
118
Spare Parts
119
Ordering Spare Parts
119
Table 50: Customer Spare Part Set (97070)
119
Table 51: Customer Spare Part Set (97071)
120
Spare Part - Illustrations
121
Table 52: Spare Parts - Bearing Casing Common Parts
122
Table 53: Spare Parts - Bearing Casing Oil Tank
124
Table 54: Spare Parts - Cartridge
125
Table 55: Spare Parts - Compressor Casing
127
Table 56: Spare Parts - Filter Silencer
128
Table 57: Spare Parts - Gas Inlet Casing Axial
129
Table 58: Spare Parts - Gas Inlet Casing Radial
130
Table 59: Spare Parts - Gas Outlet Casing
131
Table 60: Spare Parts - Rotor and Bearing Parts
133
Table 61: Spare Parts - Sealing Air Supply for Flexible Cut-Out
134
Table 62: Spare Parts - Speed Measurement
135
Table 63: Spare Parts - U-Tube Manometer
136
Table 64: Spare Parts - Turbine Dry Cleaning Radial
138
Tools
139
Table 65: Customer Tool Set 90000
139
Figures
140
Tables
142
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Original Assembly Instructions
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ABB XAC26457 Specifications
General
Brand
ABB
Model
XAC26457
Category
Industrial Equipment
Language
English
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