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ABB XAC24837 manual available for free PDF download: Operation Manual
ABB XAC24837 Operation Manual (148 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 23.11 MB
Table of Contents
Operation Manual / A200-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
22
Safe Maintenance
22
Turbocharger Weight
28
Removing the Turbocharger
28
Table 3: Total Weight
28
Removal and Installation
28
Fig. 7: Fitting the Lifting Gear
29
Installing the Turbocharger
30
Fig. 8: Placing the Turbocharger
30
Fig. 9: Compressor-End Foot
31
Fig. 10: Turbine-End Foot
31
Table 4: General Information about Fastening the Turbocharger
31
Table 5: Tightening Torques (Foot Screws)
32
Table 6: Tightening Angle (Foot Screws)
32
Inspection Procedures
33
Commissioning
33
Oil Supply
33
Commissioning after Taking out of Operation
35
Monitoring During Operation
36
Oil Pressure, Oil Temperature
36
Table 7: Lubricating Oil Pressure, Oil Inlet
36
Fig. 11: Oil Temperature at the Outlet
37
Table 8: Lubricating Oil Temperature at the Inlet
37
Table 9: Lubricating Oil Temperature at the Outlet
37
Admissible Air Inlet Temperature
39
Turbocharger Speed
39
Fig. 12: Layout and Overview of the Speed Measurement System
39
Table 10: Tightening Torques (86505)
41
Fig. 13: Replacing the Speed Sensor
41
Low Pressure Measurement at the Filter Silencer
42
Fig. 14: U-Tube Manometer at the Filter Silencer
42
Operation and Service
43
Noise Emission
43
Service Work
44
Fig. 15: Noise Insulation, Bellows
44
Expected Replacement Intervals
48
Table 11: Expected Replacement Intervals for Turbocharger Parts
48
Table 12: Recommended Replacement Intervals for Turbocharger Parts
48
Flexible Turbocharger Cut-Out
49
Stopping the Engine
50
Periodic Maintenance
51
Foreword to Maintenance
51
Cleaning the Filter Silencer
52
Fig. 16: Layout and Overview of Filter Silencer
52
Changing the Filter Strip on the Filter Silencer Casing
54
Fig. 17: Dismantling Filter Ring Circumferential Part
54
Fig. 18: Opening Filter Ring Lock
54
Fig. 19: Attaching New Filter Ring
55
Fig. 20: Fitting New Filter Ring
55
Cleaning the Compressor During Operation
56
Fig. 21: Overview of Wet Cleaning of Compressor
58
Fig. 22: Filter Plug View
59
Table 13: Volume of Water Per Cleaning Process
59
Table 14: Tightening Torques (81125)
59
Cleaning the Turbine During Operation
60
Fig. 23: Dry Cleaning Device
61
Table 15: Cleaning Parameters
63
Draining the Gas Outlet Casing
64
Fig. 24: Drain Pipe Diagram
64
Troubleshooting
65
Malfunctions When Starting
65
Table 16: Malfunctions When Starting - Delayed Start-Up
65
Table 17: Malfunctions When Starting - Vibrations
65
Table 18: Malfunctions When Starting - Rubbing of Rotating Parts
65
Malfunctions During Operation
66
Table 19: Malfunctions During Operation - Lubricating Oil Pressure too Low
66
Table 20: Malfunctions During Operation - Drop in Speed
66
Table 21: Malfunctions During Operation - Exhaust Gas Temperature too High
67
Table 22: Malfunctions During Operation - Charge Air Pressure too Low
67
Table 24: Surging of the Turbocharger
68
Table 23: Malfunctions During Operation - Charge Air Pressure too High
68
Surging of the Turbocharger
68
Malfunctions When Stopping
69
Table 25: Malfunctions When Stopping - Runout Noises
69
Table 26: Malfunctions When Stopping - Shortened Runout Time
69
Speed Measurement System
70
Table 27: Malfunctions of the Speed Measurement System
70
Disassembly and Assembly
72
Introduction
72
Material Required
73
Weights of Assemblies
74
Fig. 25: Weights of Assemblies
74
Table 28: Weights of Assemblies [Kg]
74
Table 29: Weight of Wall Insert [Kg]
74
Disassembly and Assembly of the Filter Silencer Casing
75
Fig. 26: Dismantling the Filter Silencer Casing
75
Fig. 27: Fitting the Filter Silencer Casing
76
Fig. 28: Fitting the Filter Silencer Casing
77
Fig. 29: Fitting the Filter Silencer Casing
77
Fig. 30: Fitting the Filter Silencer Casing
78
Fig. 31: Fitting the Filter Silencer Casing
78
Fig. 32: Fitting the Bellows
79
Table 30: Tightening Torques (Filter Silencer Screws)
79
Dismantling the Filter Silencer
80
Fig. 33: Dismantling the Filter Silencer
80
Fig. 34: Dismantling the Filter Silencer
81
Dismantling Wall Insert and Diffuser
82
Fig. 37: Putting down Wall Insert
83
Fig. 36: Moving out Wall Insert
83
Fig. 39: Moving out Wall Insert
85
Fig. 40: Putting down Wall Insert
85
Fig. 41: Putting down Wall Insert
86
Fig. 42: Dismantling the Diffuser
87
Axial Clearance a Prior to Disassembly
88
Fig. 43: Measuring Axial Clearance a
88
Table 31: Axial Clearance a
88
Dismantling the Insulation (≤ A275-L)
89
Fig. 44: Removing the Insulation (A275-L and Smaller)
89
Dismantling the Gas Inlet Casing (≤ A275-L)
90
Fig. 45: Dismantling the Gas Inlet Casing (275-L and Smaller)
90
Table 32: Maximum Admissible Loosening Torque (51087)
90
Dismantling the Nozzle Ring (≤ A275-L)
91
Fig. 46: Dismantling the Nozzle Ring (A275-L and Smaller)
91
Dismantling the Gas Inlet Casing (A280-L)
92
Fig. 47: Dismantling the Gas Inlet Casing (A280-L)
92
Table 33: Maximum Admissible Loosening Torque (51087)
92
Dismantling the Nozzle Ring (A280-L)
93
Fig. 48: Fitting the Nozzle Ring Holder
93
Fig. 49: Dismantling the Nozzle Ring
94
Fig. 50: Put down the Nozzle Ring
94
Fitting the Nozzle Ring (≤ A275-L)
95
Fig. 51: Fitting the Nozzle Ring (A275-L and Smaller)
95
Table 34: Tightening Torque (56014)
95
Table 35: Tightening Torque (51087)
96
Fig. 52: Fitting the Gas Outlet Casing (A275-L and Smaller)
96
Fitting the Gas Inlet Casing (≤ A275-L)
96
Fitting the Insulation (≤ A275-L)
97
Fig. 53: Fitting the Insulation (A275-L and Smaller)
97
Fitting the Nozzle Ring (A280-L)
98
Fig. 54: Fitting the Nozzle Ring (A280-L)
98
Fig. 55: Attaching the Nozzle Ring (A280-L)
99
Table 36: Tightening Torque (56014)
99
Fitting the Gas Inlet Casing (A280-L)
100
Fig. 56: Fitting the Gas Inlet Casing (A280-L)
100
Table 37: Tightening Torque (51087)
100
Axial Clearance a after Assembly
101
Fig. 57: Measuring Axial Clearance a
101
Table 38: Axial Clearance a
101
Table 39: Tightening Torque (77015)
102
Fig. 58: Fitting the Diffuser
102
Fitting the Diffuser
102
Fitting Wall Insert
103
Fig. 59: Positioning Wall Insert
103
Table 40: Tightening Torque (72002)
104
Table 41: Tightening Torque (72004)
104
Table 42: Tightening Torque (72011)
106
Fitting the Filter Silencer
107
Fig. 62: Fitting the Filter Silencer
108
Table 43: Tightening Torque (72004)
108
Fig. 63: Fitting the Filter Silencer
109
Table 44: Tightening Torque (72004)
109
Fig. 65: Overview of Speed Sensor Tightening Torque
110
Table of Tightening Torques
110
Fig. 64: Overview of Tightening Torques
111
Table 45: Overview of Tightening Torques
111
Table 46: Tightening Torque, Insulation
111
Taking a Turbocharger out of Operation
112
Possible Emergency Repairs
112
Taking Defective Turbochargers out of Operation
113
Table 47: Bypass Procedure
113
Fig. 66: Locking the Rotor
114
Table 48: Tightening Torque B
115
Fig. 67: Ensuring Clamping of the Cover Ring
116
Table 49: Required Washers (01)
116
Table 50: Tightening Torque (57005)
116
Fig. 68: Position of Cover Plates
117
Taking the Engine out of Operation for up to 12 Months
118
Mothballing the Turbocharger
118
Taking the Engine out of Operation for more than 12 Months
119
Material and Disposal
120
REACH and Rohs Compliance Declaration for Products
120
Disposing of Turbocharger Components
121
Spare Parts
122
Ordering Spare Parts
122
Table 51: Customer Spare Part Set (97070)
122
Table 52: Customer Spare Part Set (97071)
123
Spare Part - Illustrations
124
Table 53: Spare Parts - Bearing Casing Common Parts
125
Table 54: Spare Parts - Bearing Casing Oil Tank
127
Table 55: Spare Parts - Cartridge
128
Table 56: Spare Parts - Compressor Casing
130
Table 57: Spare Parts - Filter Silencer
131
Table 58: Spare Parts - Gas Inlet Casing Axial
132
Table 59: Spare Parts - Gas Inlet Casing Radial
133
Table 60: Spare Parts - Gas Outlet Casing
134
Table 61: Spare Parts - Rotor and Bearing Parts
136
Table 62: Spare Parts - Sealing Air Supply for Flexible Cut-Out
137
Table 63: Spare Parts - Speed Measurement
138
Table 64: Spare Parts - U-Tube Manometer
139
Table 65: Spare Parts - Turbine Dry Cleaning Radial
141
Tools
142
Table 67: Customer Tool Set 90000 (A265-L
142
Table 69: Customer Tool Set 90000 (A280-L
143
Figures
144
Tables
146
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