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A200-L
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Operation Manual / A200-L
7 Periodic maintenance / 7.1 Foreword to maintenance
© Copyright 2021 ABB. All rights reserved.
HZTL4036_EN
Rev.T
December 2021
7
Periodic maintenance
7.1
Foreword to maintenance
Maintenance work includes regular visual controls and cleaning operations which are inten-
ded to ensure the trouble-free functioning of the turbocharger.
Described maintenance points:
¡
Filter silencer
¡
Compressor
¡
Turbine and nozzle ring
Page 49 / 145
48
50
Table of Contents
Table of Contents
1
Introduction
4
Essential Information
5
Registered Trademarks
5
Layout and Function of the Turbocharger
6
Fig. 1: Layout and Function of the Turbocharger
6
Locations of the Rating Plates
8
Fig. 2: Locations of the Rating Plates
8
Safety
9
Introduction
9
CE Conformity
9
Table 2: Personal Protective Equipment to be Worn Specific to the Respective Task
10
Table 1: Personal Protective Equipment to be Worn at All Times
10
Definition of Safety Instructions
10
Definition of Mandatory Signs
10
Intended Use
11
Deflagration on Gas Engines
12
Warning Plates on the Turbocharger
13
Turbocharger Rating Plate
13
Fig. 3: Warning Plate Locations
13
Fig. 4: Rating Plate
13
Periodic Check of the Pressure Vessels
15
Lifting of Loads
16
Fig. 5: Attachment of Loads on the Crane Hook
16
Fig. 6: Attachment Angle
16
Prerequisites for Operation and Maintenance
17
Hazards During Operation and Maintenance
18
Safe Operation
20
Safe Maintenance
20
Turbocharger Weight
26
Removing the Turbocharger
26
Table 3: Total Weight
26
Removal and Installation
26
Fig. 7: Fitting the Lifting Gear
27
Installing the Turbocharger
28
Fig. 8: Placing the Turbocharger
28
Fig. 9: Compressor-End Foot
29
Fig. 10: Turbine-End Foot
29
Table 4: General Information about Fastening the Turbocharger
29
Table 5: Tightening Torques (Foot Screws)
30
Table 6: Tightening Angle (Foot Screws)
30
Inspection Procedures
31
Commissioning
31
Oil Supply
31
Commissioning after Taking out of Operation
33
Monitoring During Operation
34
Oil Pressure, Oil Temperature
34
Table 7: Lubricating Oil Pressure, Oil Inlet
34
Fig. 11: Oil Temperature at the Outlet
35
Table 8: Lubricating Oil Temperature at the Inlet
35
Table 9: Lubricating Oil Temperature at the Outlet
35
Admissible Air Inlet Temperature
37
Turbocharger Speed
37
Fig. 12: Layout and Overview of the Speed Measurement System
37
Table 10: Tightening Torques (86505)
39
Fig. 13: Replacing the Speed Sensor
39
Low Pressure Measurement at the Filter Silencer
40
Fig. 14: U-Tube Manometer at the Filter Silencer
40
Operation and Service
41
Noise Emission
41
Service Work
42
Fig. 15: Noise Insulation, Bellows
42
Expected Replacement Intervals
46
Table 11: Expected Replacement Intervals for Turbocharger Parts
46
Table 12: Recommended Replacement Intervals for Turbocharger Parts
46
Flexible Turbocharger Cut-Out
47
Stopping the Engine
48
Periodic Maintenance
49
Foreword to Maintenance
49
Cleaning the Filter Silencer
50
Fig. 16: Layout and Overview of Filter Silencer
50
Changing the Filter Strip on the Filter Silencer Casing
52
Fig. 17: Dismantling Filter Ring Circumferential Part
52
Fig. 18: Opening Filter Ring Lock
52
Fig. 19: Attaching New Filter Ring
53
Fig. 20: Fitting New Filter Ring
53
Cleaning the Compressor During Operation
54
Fig. 21: Overview of Wet Cleaning of Compressor
56
Fig. 22: Filter Plug View
57
Table 13: Volume of Water Per Cleaning Process
57
Table 14: Tightening Torques (81125)
57
Cleaning the Turbine During Operation
58
Fig. 23: Dry Cleaning Device
59
Table 15: Cleaning Parameters
61
Draining the Gas Outlet Casing
62
Fig. 24: Drain Pipe Diagram
62
Troubleshooting
63
Malfunctions When Starting
63
Table 16: Malfunctions When Starting - Delayed Start-Up
63
Table 17: Malfunctions When Starting - Vibrations
63
Table 18: Malfunctions When Starting - Rubbing of Rotating Parts
63
Malfunctions During Operation
64
Table 19: Malfunctions During Operation - Lubricating Oil Pressure too Low
64
Table 20: Malfunctions During Operation - Drop in Speed
64
Table 21: Malfunctions During Operation - Exhaust Gas Temperature too High
65
Table 22: Malfunctions During Operation - Charge Air Pressure too Low
65
Table 24: Surging of the Turbocharger
66
Table 23: Malfunctions During Operation - Charge Air Pressure too High
66
Surging of the Turbocharger
66
Malfunctions When Stopping
67
Table 25: Malfunctions When Stopping - Runout Noises
67
Table 26: Malfunctions When Stopping - Shortened Runout Time
67
Speed Measurement System
68
Table 27: Malfunctions of the Speed Measurement System
68
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
Disassembly and Assembly of the Filter Silencer Casing
73
Fig. 26: Dismantling 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 Wall Insert and Diffuser
80
Fig. 37: Putting down Wall Insert
81
Fig. 36: Moving out Wall Insert
81
Fig. 39: Moving out Wall Insert
83
Fig. 40: Putting down Wall Insert
83
Fig. 41: Putting down Wall Insert
84
Fig. 42: Dismantling the Diffuser
85
Axial Clearance a Prior to Disassembly
86
Fig. 43: Measuring Axial Clearance a
86
Table 31: Axial Clearance a
86
Dismantling the Insulation (≤ A275-L)
87
Fig. 44: Removing the Insulation (A275-L and Smaller)
87
Dismantling the Gas Inlet Casing (≤ A275-L)
88
Fig. 45: Dismantling the Gas Inlet Casing (275-L and Smaller)
88
Table 32: Maximum Admissible Loosening Torque (51087)
88
Dismantling the Nozzle Ring (≤ A275-L)
89
Fig. 46: Dismantling the Nozzle Ring (A275-L and Smaller)
89
Dismantling the Gas Inlet Casing (A280-L)
90
Fig. 47: Dismantling the Gas Inlet Casing (A280-L)
90
Table 33: Maximum Admissible Loosening Torque (51087)
90
Dismantling the Nozzle Ring (A280-L)
91
Fig. 48: Fitting the Nozzle Ring Holder
91
Fig. 49: Dismantling the Nozzle Ring
92
Fig. 50: Put down the Nozzle Ring
92
Fitting the Nozzle Ring (≤ A275-L)
93
Fig. 51: Fitting the Nozzle Ring (A275-L and Smaller)
93
Table 34: Tightening Torque (56014)
93
Table 35: Tightening Torque (51087)
94
Fig. 52: Fitting the Gas Outlet Casing (A275-L and Smaller)
94
Fitting the Gas Inlet Casing (≤ A275-L)
94
Fitting the Insulation (≤ A275-L)
95
Fig. 53: Fitting the Insulation (A275-L and Smaller)
95
Fitting the Nozzle Ring (A280-L)
96
Fig. 54: Fitting the Nozzle Ring (A280-L)
96
Fig. 55: Attaching the Nozzle Ring (A280-L)
97
Table 36: Tightening Torque (56014)
97
Fitting the Gas Inlet Casing (A280-L)
98
Fig. 56: Fitting the Gas Inlet Casing (A280-L)
98
Table 37: Tightening Torque (51087)
98
Axial Clearance a after Assembly
99
Fig. 57: Measuring Axial Clearance a
99
Table 38: Axial Clearance a
99
Table 39: Tightening Torque (77015)
100
Fig. 58: Fitting the Diffuser
100
Fitting the Diffuser
100
Fitting Wall Insert
101
Fig. 59: Positioning Wall Insert
101
Table 40: Tightening Torque (72002)
102
Table 41: Tightening Torque (72004)
102
Table 42: Tightening Torque (72011)
104
Fitting the Filter Silencer
105
Fig. 62: Fitting the Filter Silencer
106
Table 43: Tightening Torque (72004)
106
Fig. 63: Fitting the Filter Silencer
107
Table 44: Tightening Torque (72004)
107
Fig. 65: Overview of Speed Sensor Tightening Torque
108
Table of Tightening Torques
108
Fig. 64: Overview of Tightening Torques
109
Table 45: Overview of Tightening Torques
109
Table 46: Tightening Torque, Insulation
109
Taking a Turbocharger out of Operation
110
Possible Emergency Repairs
110
Taking Defective Turbochargers out of Operation
111
Table 47: Bypass Procedure
111
Fig. 66: Locking the Rotor
112
Table 48: Tightening Torque B
113
Fig. 67: Ensuring Clamping of the Cover Ring
114
Table 49: Required Washers (01)
114
Table 50: Tightening Torque (57005)
114
Fig. 68: Position of Cover Plates
115
Taking the Engine out of Operation for up to 12 Months
116
Mothballing the Turbocharger
116
Taking the Engine out of Operation for more than 12 Months
117
Material and Disposal
118
REACH and Rohs Compliance Declaration for Products
118
Disposing of Turbocharger Components
119
Spare Parts
120
Ordering Spare Parts
120
Table 51: Customer Spare Part Set (97070)
120
Table 52: Customer Spare Part Set (97071)
121
Spare Part - Illustrations
122
Table 53: Spare Parts - Bearing Casing Common Parts
123
Table 54: Spare Parts - Bearing Casing Oil Tank
125
Table 55: Spare Parts - Cartridge
126
Table 56: Spare Parts - Compressor Casing
128
Table 57: Spare Parts - Filter Silencer
129
Table 58: Spare Parts - Gas Inlet Casing Axial
130
Table 59: Spare Parts - Gas Inlet Casing Radial
131
Table 60: Spare Parts - Gas Outlet Casing
132
Table 61: Spare Parts - Rotor and Bearing Parts
134
Table 62: Spare Parts - Sealing Air Supply for Flexible Cut-Out
135
Table 63: Spare Parts - Speed Measurement
136
Table 64: Spare Parts - U-Tube Manometer
137
Table 65: Spare Parts - Turbine Dry Cleaning Radial
139
Tools
140
Table 67: Customer Tool Set 90000 (A265-L
140
Table 69: Customer Tool Set 90000 (A280-L
141
Figures
142
Tables
144
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Assembly Instructions
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ABB A200-L Specifications
General
Brand
ABB
Model
A200-L
Category
Battery Charger
Language
English
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