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ABB XAC22399 manual available for free PDF download: Operation Manual
ABB XAC22399 Operation Manual (136 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 22.76 MB
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: Total Weight
36
Turbocharger Weight
36
Fig. 4: Fitting the Lifting Gear
37
Fig. 5: Placing the Turbocharger
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
Fig. 8: Oil Temperature at the Outlet
45
Table 7: Lubricating Oil Temperature at the Inlet
45
Table 8: Lubricating Oil Temperature at the Outlet
45
Admissible Air Inlet Temperature
47
Fig. 9: Layout and Overview of the Speed Measurement System
47
Turbocharger Speed
47
Fig. 10: Replacing the Speed Sensor
49
Table 9: Tightening Torques (86505)
49
Fig. 11: U-Tube Manometer at the Filter Silencer
50
Low Pressure Measurement at the Filter Silencer
50
Noise Emission
51
Operation and Service
51
Fig. 12: Noise Insulation, Bellows
52
Service Work
52
Expected Replacement Intervals
56
Table 10: Expected Replacement Intervals for Turbocharger Parts
56
Table 11: Recommended Replacement Intervals for Turbocharger Parts
56
Flexible Turbocharger Cut-Out
57
Stopping the Engine
58
Foreword to Maintenance
59
Periodic Maintenance
59
Cleaning the Filter Silencer
60
Fig. 13: Layout and Overview of Filter Silencer
60
Changing the Filter Strip on the Filter Silencer Casing
62
Fig. 14: Dismantling Filter Ring Circumferential Part
62
Fig. 15: Opening Filter Ring Lock
62
Fig. 16: Attaching New Filter Ring
63
Fig. 17: Fitting New Filter Ring
63
Cleaning the Compressor During Operation
64
Fig. 18: Overview of Wet Cleaning of Compressor
66
Fig. 19: Filter Plug View
67
Table 12: Volume of Water Per Cleaning Process
67
Table 13: Tightening Torques (81125)
67
Cleaning the Turbine During Operation
68
Fig. 20: Overview of Dry Cleaning Device
69
Table 14: Amount of Granulate
71
Draining the Gas Outlet Casing
72
Fig. 21: Drain Pipe Diagram
72
Malfunctions When Starting
73
Table 15: Malfunctions When Starting - Delayed Start-Up
73
Table 16: Malfunctions When Starting - Vibrations
73
Table 17: Malfunctions When Starting - Rubbing of Rotating Parts
73
Troubleshooting
73
Malfunctions During Operation
74
Table 18: Malfunctions During Operation - Lubricating Oil Pressure too Low
74
Table 19: Malfunctions During Operation - Drop in Speed
74
Table 20: Malfunctions During Operation - Exhaust Gas Temperature too High
75
Table 21: Malfunctions During Operation - Charge Air Pressure too Low
75
Surging of the Turbocharger
76
Table 22: Malfunctions During Operation - Charge Air Pressure too High
76
Table 23: Surging of the Turbocharger
76
Malfunctions When Stopping
77
Table 24: Malfunctions When Stopping - Runout Noises
77
Table 25: Malfunctions When Stopping - Shortened Runout Time
77
Speed Measurement System
78
Table 26: Malfunctions of the Speed Measurement System
78
Disassembly and Assembly
79
Introduction
79
Fig. 22: Weights of Assemblies
81
Table 27: Weights of Assemblies [Kg]
81
Table 28: Weight of Wall Insert [Kg]
81
Weights of Assemblies
81
Disassembly and Assembly of the Filter Silencer Casing
82
Fig. 23: Dismantling the Filter Silencer Casing
82
Fig. 24: Fitting the Filter Silencer Casing
83
Fig. 25: Fitting the Filter Silencer Casing
84
Fig. 26: Fitting the Filter Silencer Casing
84
Fig. 27: Fitting the Filter Silencer Casing
85
Fig. 28: Fitting the Filter Silencer Casing
85
Fig. 29: Fitting the Bellows
86
Table 29: Tightening Torques (Filter Silencer Screws)
86
Dismantling the Filter Silencer
87
Fig. 30: Dismantling the Filter Silencer
87
Fig. 31: Dismantling the Filter Silencer
88
Dismantling the Filter Silencer with Noise Package
89
Fig. 32: Dismantling the Filter Silencer with Noise Package
89
Dismantling Wall Insert and Diffuser
90
Fig. 33: Dismantling the Wall Insert
90
Fig. 34: Moving out Wall Insert
91
Fig. 35: Putting down Wall Insert
91
Fig. 36: Putting down Wall Insert
92
Fig. 37: Dismantling the Diffuser
93
Axial Clearance a Prior to Disassembly
94
Fig. 38: Measuring Axial Clearance a
94
Table 30: Axial Clearance a
94
Dismantling the Insulation (≤ A175-L)
95
Fig. 39: Removing the Insulation (A175-L and Smaller)
95
Dismantling the Gas Inlet Casing (≤ A175-L)
96
Fig. 40: Dismantling the Gas Inlet Casing (A175-L and Smaller)
96
Table 31: Maximum Admissible Loosening Torque (51087)
96
Dismantling the Nozzle Ring (≤ A175-L)
97
Fig. 41: Dismantling the Nozzle Ring (A175-L and Smaller)
97
Dismantling the Gas Inlet Casing (≥ A180-L)
98
Fig. 42: Dismantling the Gas Inlet Casing (180-L and Larger)
98
Table 32: Maximum Admissible Loosening Torque (51087)
98
Dismantling the Nozzle Ring (≥ A180-L)
99
Fig. 43: Fitting the Nozzle Ring Holder
99
Fig. 44: Dismantling the Nozzle Ring
100
Fig. 45: Put down the Nozzle Ring
100
Fig. 46: Fitting the Nozzle Ring (A175-L and Smaller)
101
Fitting the Nozzle Ring (≤ A175-L)
101
Table 33: Tightening Torque (56014)
101
Fig. 47: Fitting the Gas Outlet Casing (A175-L and Smaller)
102
Fitting the Gas Inlet Casing (≤ A175-L)
102
Table 34: Tightening Torque (51087)
102
Fig. 48: Fitting the Insulation (A175-L and Smaller)
103
Fitting the Insulation (≤ A175-L)
103
Fig. 49: Looping Around the Nozzle Ring (A180-L and Larger)
104
Fitting the Nozzle Ring (≥ A180-L)
104
Fig. 50: Fitting the Nozzle Ring (A180-L and Larger)
105
Table 35: Tightening Torque (56014)
105
Fig. 51: Fitting the Gas Inlet Casing (A180-L and Larger)
106
Fitting the Gas Inlet Casing (≥ A180-L)
106
Table 36: Tightening Torque (51087)
106
Axial Clearance a after Assembly
107
Fig. 52: Measuring Axial Clearance a
107
Table 37: Axial Clearance a
107
Fig. 53: Fitting the Diffuser
108
Fitting the Diffuser
108
Table 38: Tightening Torque (77015)
108
Fig. 54: Positioning Wall Insert
109
Fitting Wall Insert
109
Fig. 55: Fitting Wall Insert
110
Table 39: Tightening Torque (72011)
110
Fitting the Filter Silencer
111
Table 40: Tightening Torque (72004)
112
Fig. 56: Fitting the Filter Silencer
113
Fig. 57: Fitting the Filter Silencer
113
Table 41: Tightening Torque (72004)
113
Fig. 58: Fitting the Filter Silencer with Noise Package
114
Fitting the Filter Silencer with Noise Package
114
Table 42: Tightening Torque (51087)
114
Fig. 60: Tightening Torques of Speed Sensor
116
Table of Tightening Torques
116
Fig. 59: Overview of Tightening Torques
117
Table 43: Overview of Tightening Torques
117
Table 44: Tightening Torque, Insulation
117
Possible Emergency Repairs
118
Taking a Turbocharger out of Operation
118
Table 45: Bypass Procedure
119
Taking Defective Turbochargers out of Operation
119
Fig. 61: Locking the Rotor
120
Table 46: Tightening Torque
121
Fig. 62: Ensuring Clamping of the Cover Ring
122
Table 47: Required Washers (01)
122
Table 48: Tightening Torque (57005)
122
Fig. 63: Position of Cover Plates
123
Mothballing the Turbocharger
125
Taking the Engine out of Operation for up to 12 Months
125
Taking the Engine out of Operation for more than 12 Months
126
Disposing of Turbocharger Components
127
Ordering Spare Parts
128
Spare Parts
128
Table 49: Customer Spare Part Set (97070)
128
Table 50: Customer Spare Part Set (97071)
129
Fig. 64: View of Turbocharger with Part Numbers
130
View of Turbocharger with Part Numbers
130
Table 51: Turbocharger with Part Numbers
131
Fig. 65: 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
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