ABB XAC24084 User manual

Turbo Systems Switzerland Ltd
Operation Manual / A165-L35
XAC24084
Document identification
Document number HZTL4034
Revision T
Language English
Original Operation Manual
Product identification
Serial number XAC24084
Customer part number AV65MZ01281
Delivery date (yyyy-mm-dd) 2021-04-16
Weight 2300 kg
Operating limits according to rating plate
Speed limit in test rig operation only nMmax 365 1/s
Speed limit during operation nBmax 342 1/s
Gas inlet temperature limit in test rig operation only tMmax 550 °C
Gas inlet temperature limit during operation tBmax 520 °C

Operation Manual / A100-L
Table of contents
© Copyright 2021 ABB. All rights reserved. HZTL4034_EN Rev.T December 2021
Operation Manual / A100-L
1 Introduction............................................................................................................ 4
1.1 Essential information.................................................................................................... 5
1.2 Registered trademarks................................................................................................. 5
1.3 Layout and function of the turbocharger ................................................................ 6
1.4 Locations of the rating plates.................................................................................... 8
2 Safety ...................................................................................................................... 9
2.1 Introduction ................................................................................................................... 9
2.2 CE conformity................................................................................................................ 9
2.3 Definition of mandatory signs .................................................................................. 10
2.4 Definition of safety instructions .............................................................................. 10
2.5 Intended use ................................................................................................................. 11
2.6 Deflagration on gas engines ..................................................................................... 12
2.7 Warning plates on the turbocharger........................................................................ 13
2.8 Turbocharger rating plate.......................................................................................... 13
2.9 Periodic check of the pressure vessels.................................................................... 15
2.10 Lifting of loads ............................................................................................................. 16
2.11 Prerequisites for operation and maintenance....................................................... 17
2.12 Hazards during operation and maintenance ......................................................... 18
2.13 Safe operation.............................................................................................................. 19
2.14 Safe maintenance ....................................................................................................... 20
3 Removal and installation .................................................................................... 25
3.1 Turbocharger weight ................................................................................................. 25
3.2 Removing the turbocharger...................................................................................... 25
3.3 Installing the turbocharger ....................................................................................... 27
4 Commissioning .................................................................................................... 30
4.1 Oil supply ...................................................................................................................... 30
4.2 Inspection procedures............................................................................................... 30
4.3 Commissioning after taking out of operation....................................................... 32
5 Monitoring during operation.............................................................................. 33
5.1 Oil pressure, oil temperature.................................................................................... 33
5.2 Admissible air inlet temperature ............................................................................. 36
5.3 Turbocharger speed ................................................................................................... 36
5.4 Low pressure measurement at the filter silencer ................................................ 39
6 Operation and service ......................................................................................... 40
6.1 Noise emission ............................................................................................................ 40
6.2 Service work.................................................................................................................. 41
6.3 Expected replacement intervals .............................................................................. 45
6.4 Flexible turbocharger cut-out .................................................................................. 46

Operation Manual / A100-L
Table of contents
© Copyright 2021 ABB. All rights reserved. HZTL4034_EN Rev.T December 2021
6.5 Stopping the engine................................................................................................... 47
7 Periodic maintenance.......................................................................................... 48
7.1 Foreword to maintenance......................................................................................... 48
7.2 Cleaning the filter silencer ........................................................................................ 49
7.3 Changing the filter strip on the filter silencer casing........................................... 51
7.4 Cleaning the compressor during operation .......................................................... 53
7.5 Cleaning the turbine during operation.................................................................... 57
7.6 Draining the gas outlet casing .................................................................................. 61
8 Troubleshooting................................................................................................... 62
8.1 Malfunctions when starting...................................................................................... 62
8.2 Malfunctions during operation ................................................................................ 63
8.3 Surging of the turbocharger..................................................................................... 65
8.4 Malfunctions when stopping.................................................................................... 66
8.5 Speed measurement system.................................................................................... 67
9 Disassembly and assembly................................................................................. 68
9.1 Introduction ................................................................................................................. 68
9.2 Material required......................................................................................................... 69
9.3 Weights of assemblies............................................................................................... 70
9.4 Disassembly and assembly of the filter silencer casing ...................................... 71
9.5 Dismantling the filter silencer .................................................................................. 76
9.6 Dismantling the filter silencer with noise package ............................................. 78
9.7 Dismantling wall insert and diffuser....................................................................... 79
9.8 Axial clearance A prior to disassembly ................................................................... 83
9.9 Dismantling the insulation (≤ A175-L)..................................................................... 84
9.10 Dismantling the gas inlet casing (≤ A175-L) .......................................................... 85
9.11 Dismantling the nozzle ring (≤ A175-L) ................................................................... 86
9.12 Dismantling the gas inlet casing (≥ A180-L).......................................................... 87
9.13 Dismantling the nozzle ring (≥ A180-L)................................................................... 88
9.14 Fitting the nozzle ring (≤ A175-L) ............................................................................. 90
9.15 Fitting the gas inlet casing (≤ A175-L) ..................................................................... 91
9.16 Fitting the insulation (≤ A175-L)............................................................................... 92
9.17 Fitting the nozzle ring (≥ A180-L) ............................................................................ 93
9.18 Fitting the gas inlet casing (≥ A180-L).................................................................... 95
9.19 Axial clearance A after assembly.............................................................................. 96
9.20 Fitting the diffuser ..................................................................................................... 97
9.21 Fitting wall insert ........................................................................................................ 98
9.22 Fitting the filter silencer.......................................................................................... 100
9.23 Fitting the filter silencer with noise package ..................................................... 103
9.24 Table of tightening torques.................................................................................... 105
10 Taking a turbocharger out of operation......................................................... 107
10.1 Possible emergency repairs.................................................................................... 107
10.2 Taking defective turbochargers out of operation ............................................. 108
11 Mothballing the turbocharger........................................................................... 113

Operation Manual / A100-L
Table of contents
© Copyright 2021 ABB. All rights reserved. HZTL4034_EN Rev.T December 2021
11.1 Taking the engine out of operation for up to 12months .................................. 113
11.2 Taking the engine out of operation for more than 12months ......................... 114
12 Material and Disposal........................................................................................ 115
12.1 REACH and RoHS Compliance Declaration For Products .................................. 115
12.2 Disposing of turbocharger components .............................................................. 116
13 Spare parts .......................................................................................................... 117
13.1 Ordering spare parts................................................................................................. 117
13.2 Spare Part - Illustrations........................................................................................... 119
14 Tools .................................................................................................................... 137
Figures................................................................................................................. 138
Tables .................................................................................................................. 140