ABB XAC26339 User manual

Turbo Systems Switzerland Ltd
Operation Manual / A255-L32
XAC26339
Document identification
Document number HZTL4036
Revision T
Language English
Original Operation Manual
Product identification
Serial number XAC26339
Customer part number A255MK00311
Delivery date (yyyy-mm-dd) 2022-04-14
Weight 1500 kg
Operating limits according to rating plate
Speed limit in test rig operation only nMmax 472 1/s
Speed limit during operation nBmax 454 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 / A200-L
Table of contents
© Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021
Operation Manual / A200-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............................................................................................................. 20
2.14 Safe maintenance ....................................................................................................... 20
3 Removal and installation .................................................................................... 26
3.1 Turbocharger weight ................................................................................................. 26
3.2 Removing the turbocharger...................................................................................... 26
3.3 Installing the turbocharger ...................................................................................... 28
4 Commissioning .................................................................................................... 31
4.1 Oil supply ....................................................................................................................... 31
4.2 Inspection procedures................................................................................................ 31
4.3 Commissioning after taking out of operation...................................................... 33
5 Monitoring during operation.............................................................................. 34
5.1 Oil pressure, oil temperature.................................................................................... 34
5.2 Admissible air inlet temperature .............................................................................. 37
5.3 Turbocharger speed .................................................................................................... 37
5.4 Low pressure measurement at the filter silencer ................................................ 40
6 Operation and service ......................................................................................... 41
6.1 Noise emission ............................................................................................................. 41
6.2 Service work................................................................................................................. 42
6.3 Expected replacement intervals .............................................................................. 46
6.4 Flexible turbocharger cut-out .................................................................................. 47

Operation Manual / A200-L
Table of contents
© Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021
6.5 Stopping the engine................................................................................................... 48
7 Periodic maintenance.......................................................................................... 49
7.1 Foreword to maintenance......................................................................................... 49
7.2 Cleaning the filter silencer ........................................................................................ 50
7.3 Changing the filter strip on the filter silencer casing.......................................... 52
7.4 Cleaning the compressor during operation .......................................................... 54
7.5 Cleaning the turbine during operation................................................................... 58
7.6 Draining the gas outlet casing ................................................................................. 62
8 Troubleshooting................................................................................................... 63
8.1 Malfunctions when starting...................................................................................... 63
8.2 Malfunctions during operation ................................................................................ 64
8.3 Surging of the turbocharger..................................................................................... 66
8.4 Malfunctions when stopping.................................................................................... 67
8.5 Speed measurement system.................................................................................... 68
9 Disassembly and assembly................................................................................. 70
9.1 Introduction ................................................................................................................. 70
9.2 Material required.......................................................................................................... 71
9.3 Weights of assemblies................................................................................................ 72
9.4 Disassembly and assembly of the filter silencer casing ...................................... 73
9.5 Dismantling the filter silencer .................................................................................. 78
9.6 Dismantling wall insert and diffuser....................................................................... 80
9.7 Axial clearance A prior to disassembly ................................................................... 86
9.8 Dismantling the insulation (≤ A275-L) .................................................................... 87
9.9 Dismantling the gas inlet casing (≤ A275-L) .......................................................... 88
9.10 Dismantling the nozzle ring (≤ A275-L)................................................................... 89
9.11 Dismantling the gas inlet casing (A280-L)............................................................. 90
9.12 Dismantling the nozzle ring (A280-L) ...................................................................... 91
9.13 Fitting the nozzle ring (≤ A275-L)............................................................................. 93
9.14 Fitting the gas inlet casing (≤ A275-L).................................................................... 94
9.15 Fitting the insulation (≤ A275-L) .............................................................................. 95
9.16 Fitting the nozzle ring (A280-L) ............................................................................... 96
9.17 Fitting the gas inlet casing (A280-L)....................................................................... 98
9.18 Axial clearance A after assembly.............................................................................. 99
9.19 Fitting the diffuser ................................................................................................... 100
9.20 Fitting wall insert ....................................................................................................... 101
9.21 Fitting the filter silencer.......................................................................................... 105
9.22 Table of tightening torques.................................................................................... 108
10 Taking a turbocharger out of operation......................................................... 110
10.1 Possible emergency repairs..................................................................................... 110
10.2 Taking defective turbochargers out of operation .............................................. 111
11 Mothballing the turbocharger.......................................................................... 116
11.1 Taking the engine out of operation for up to 12months .................................. 116
11.2 Taking the engine out of operation for more than 12months ......................... 117

Operation Manual / A200-L
Table of contents
© Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021
12 Material and Disposal........................................................................................ 118
12.1 REACH and RoHS Compliance Declaration For Products .................................. 118
12.2 Disposing of turbocharger components .............................................................. 119
13 Spare parts ......................................................................................................... 120
13.1 Ordering spare parts................................................................................................ 120
13.2 Spare Part - Illustrations........................................................................................... 122
14 Tools .................................................................................................................... 140
Figures................................................................................................................. 142
Tables .................................................................................................................. 144