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Operation Manual

Turbocharging

ABB Turbo Systems Ltd

ABB Turbo Systems Ltd
CH 5401 Baden

Type

TPL71-C35

HT562490

Mmax

410

Mmax

650

Bmax

410

Bmax

620

1/s

°C

02040

Year

2013

made in Switzerland

Application according to

the Operation Manual

HZTL2488 English

TPL71-C35

Original Operation Manual

Summary of Contents for HT562490

Page 1: ...ABB Turbo Systems Ltd CH 5401 Baden Type TPL71 C35 HT562490 nMmax 410 t Mmax 650 nBmax 410 t Bmax 620 1 s C 02040 35 50 50 Year 2013 made in Switzerland Application according to the Operation Manual kg HZTL2488 English TPL71 C35 Original Operation Manual ...

Page 2: ...stes or at a specialised collecting centre ABB Turbo Systems AG Bruggerstrasse 71a CH 5401 Baden Switzerland Operating condition and replacement intervals The operational limits for the turbocharger nBmax tBmax nMmax tMmax inspection and replacement intervals for the compon ents concerned on the rating plate are valid for the operational mode and compressor inlet condition which has been agreed up...

Page 3: ...ting plate 1 8 Contact information 2 Safety 2 1 Introduction 2 2 CE conformity 2 3 Definition of mandatory signs 2 4 Definition of Safety instructions 2 5 Warning plates on the turbocharger 2 6 Safe operation and maintenance 2 7 Hazards during operation and maintenance 2 8 Periodic checking of the pressure vessel 2 9 Lifting loads 3 Commissioning 3 1 Oil supply 3 2 Inspection work 3 3 Commissionin...

Page 4: ...ement system 7 Removal and installation 7 1 Turbocharger weights 7 2 Remove the turbocharger 7 3 Installing the turbocharger 8 Disassembly and assembly 8 1 Introduction 8 2 Module weights 8 3 Removing and fitting filter silencer or air suction branch 8 4 Axial clearance 8 5 Removing cartridge group 8 6 Dismantling and installing the turbine diffuser and nozzle ring 8 7 Installing cartridge group 8...

Page 5: ...sion C 10 Mothballing turbocharger 10 1 Taking out of operation for up to 12 months 10 2 Taking out of operation for more than 12 months 11 Disposing of turbocharger components 12 Spare parts 12 1 Ordering spare parts 12 2 View of turbocharger with part numbers 12 3 View of turbine cleaning system with part numbers optional ...

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Page 7: ...urbo Systems and to use it as intended It provides important information in order that the turbocharger can be op erated safely correctly and efficiently This Operation Manual complements and expands existing national regu lations concerning work safety and accident prevention Target group This Operation Manual is intended for engineers and qualified mechanics who are responsible for operating the...

Page 8: ...rved April 2016 HZTL2488_EN Revision C Layout and function 1 2 01 Filter silencer 08 Nozzle ring 02 Radial plain bearing 09 Turbine wheel 03 Thrust bearing 10 Bearing casing 04 Bearing bush 11 Diffuser 05 Radial plain bearing 12 Compressor wheel 06 Gas outlet casing 13 Compressor casing 07 Gas inlet casing 1 2 TPL67 71 C ...

Page 9: ...12 This air then passes through the diffuser 11 and leaves the turbocharger through the com pressor casing 13 The rotor runs in two radial plain bearings 02 05 One plain bearing is in the bearing bush 04 and the second one is in the axial thrust bearing 03 at the compressor end The plain bearings are connected to a central lubricating oil duct which is fed with oil from the engine s lubricating oi...

Page 10: ...ect all warranty claims This turbocharger was built according to state of the art technology and is operationally safe according to recognised safety regulations WARNING Improper operation and maintenance of the turbocharger can result in danger to life and limb of the user or third parties In addition improper use may cause damage to the machine The machine may be operated only by trained personn...

Page 11: ... when handling VCIs VCI products are not hazardous in the sense of the Hazardous Sub stances Ordinance Nevertheless the following points are to be ob served when handling VCIs Ensure good room ventilation Do not eat drink or keep food at the workplace while working with VCIs Wear safety gloves Clean hands and face after working with VCIs For further information refer to www branopac com Wear safet...

Page 12: ... Turbocharging Service Station and repacked Inspect the package for damage If the package is damaged the tur bocharger or cartridge group must be inspected by an ABB Turbo charging Service Station and repacked After every 3 years the following work steps must be performed by an ABB Turbocharging Service Station Inspect the components Exchange the desiccant agent Repackage the components NOTICE Rep...

Page 13: ...lso applies to the provision and wearing of personnel protection equipment NOTICE The safety and risk consciousness of the personnel working on and with the turbocharger must be checked regularly with reference to this manual The turbocharger must be shut down immediately by stopping the en gine in the event of alterations affecting safety or of corresponding op erating behaviour The fault must be...

Page 14: ...riginal parts Operation of the turbocharger with non original parts can impair the safety of the turbocharger and can cause serious damage to property and injury to personnel Only use original parts from ABB Turbo Systems ABB Turbo Systems accepts no liability for any damage resulting from the use of non original parts and corresponding accessories Competence of personnel The turbocharger must onl...

Page 15: ...are not rele vant for a specific turbocharger variant ABB Turbocharging Service Stations will be happy to provide information on questions regarding a design variant see Contact information at www abb com turbocharging Accuracy of illustrations The illustrations in this document are general in nature and intended for ease of understanding Differences in detail are therefore possible Registered tra...

Page 16: ...e product Definition of mandatory signs Mandatory signs show the protective equipment to be worn for a task The mandatory signs are described in chapter Safety and must be complied with Definition of caution warning The caution and warning signs are described in the chapter Safety ABB Turbo Systems In this document ABB Turbo Systems Ltd is abbreviated to ABB Turbo Systems Official ABB Turbo System...

Page 17: ...ise agreed with the en ginebuilder 02 Turbocharger operating limits during operation 03 Replacement interval for plain bearings in 1000 h 04 Replacement interval for compressor in 1000 h 05 Replacement interval for turbine in 1000 h 06 Part number for customer 07 Designation of special design 08 Turbocharger weight in kg 09 Turbocharger type 10 Serial number 11 Year of turbocharger construction 1 ...

Page 18: ...hat you contact the nearest official ABB Turbocharging service station nMmaxand tMmax normally apply only when running at overload 110 during tri als on the engine test bed These limits can also be permitted during operation for special applications Operation above nMmax and tMmax is not permitted Non observance of the recommended replacement intervals can increase the risk of unpredictable compon...

Page 19: ... reserved April 2016 HZTL2488_EN Revision C Contact information 1 8 Contact information Contact information for the official service stations of ABB Turbo Systems is available online Scan the QR code to access our website ABB Turbo Systems Ltd Bruggerstrasse 71a CH 5401 Baden Switzerland www abb com turbocharging 1 8 ...

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Page 21: ...sed are the consequence of insufficient observance of the safety instruc tions are the consequence of unsatisfactory and improper execution of maintenance and inspection work The operator is responsible for access to the turbocharger as well as the organisational measures which regulate the safe handling of the turbo charger by his personnel All instructions in this chapter must be observed to ens...

Page 22: ...ection Definition of Safety instructions 2 4 The following symbols and terms used in this manual concern safety or refer to possible hazards WARNING Definition of warning Serious personal injuries and even accidents with fatal consequences may occur if work and operating instructions marked with this symbol and the word WARNING are either not followed or not followed precise ly Warning signs must ...

Page 23: ...ttached to turbochargers by ABB Turbo Sys tems must not be removed Illegible warnings must be replaced with new ones Further information is available from ABB Turbocharging service stations Part number Size mm Product 81080 105 x 74 TPL TPR When uninsulated turbochargers are delivered to the engine builder the warning plates must be subsequently attached to the insulation This is the responsibilit...

Page 24: ...eral regulations for the prevention of accidents Do not work on the turbocharger if you are under physical or mental stress Work only with suitable tools as well as equipment and working mate rials that are in perfect condition Electric tools must be solidly earthed and connecting cables may not be damaged Keep the workplace clean clear away loose objects and remove ob stacles on the floor Keep th...

Page 25: ... any damage or changes in operational perfor mance to person responsible If damage is discovered immediately shut down turbocharger and se cure it against inadvertent or unauthorized use When switching on auxiliary power sources hydraulics pneumatics electricity water keep an eye open for any hazards resulting from supplying these power sources Safety during cleaning It is possible that detergents...

Page 26: ...e must be switched off and the turbocharger must have come to a standstill Ensure that the supply of oil is interrupted especially with an external oil supply Put the engine into operation only after all parts have been refitted properly CAUTION Mechanical work on the turbocharger Possible damage to or destruction of components on the turbocharger Perform only those tasks that are described in thi...

Page 27: ...perate the turbocharger in accordance with instructions During maintenance work secure the rotor against unintentional ro tation Mechanical hazards when working on the turbocharger During maintenance work various risks can occur through the improper handling of components through the non observance of work instructions due to inadequate care or as a consequence of insufficient training WARNING Mec...

Page 28: ...ure level is above 85 dB A always wear ear protection Wear ear protection Hazards due to hot surfaces and substances During operation turbocharger surfaces and attached parts as well as op erating materials lubricating oil become hot The surface temperature is dependent on the effectiveness of the insulation being used The tem perature can become high enough so that it falls into ranges where burn...

Page 29: ...ot turbocharger surfaces must be observed in every case Hazards due to operating and auxiliary materials Operating and auxiliary materials are substances used for operation or the execution of maintenance work Oils greases coolants cleaning agents and solvents acids etc can be regarded as hazardous materials Operat ing and auxiliary materials can be combustible and easily ignited WARNING Handling ...

Page 30: ...contamination of the ground and water due to improper disposal can lead to environmental damage Handle operating and auxiliary materials carefully Heed the instructions for use safety data sheets and hazard notices on the containers of the operating and auxiliary materials Wear appropriate protective clothing Avoid inhalation and contact with the skin Ensure that the work space is adequately venti...

Page 31: ...als only in the work area Take particular care when removing old insulating materials Dispose of insulating materials properly and in an environmentally compatible way in accordance with applicable local regulations Wear safety goggles Wear a respiratory mask to protect against particles Wear safety gloves against chemical risks Use only suitable non combustible insulating materials Ensure that th...

Page 32: ...gulations Periodic checking of the pressure vessel 2 8 The pressure vessels used by ABB Turbo Systems such as those for wet or dry cleaning are so called simple pressure vessels The local statutory regulations covering periodic checks of pressure vessels must be observed The operator is responsible for the safe operation of the pressure ves sel WARNING Hazards from pressure vessels The operator mu...

Page 33: ... stand beneath a suspended load Wear safety gloves against mechanical risks Wear safety helmet In the case of two or more suspension points the slinging angle must not exceed 45 This avoids excessive loading due to inclined tensile loading Fasten turbocharger assemblies components as described in respec tive handling steps Before attaching slings allow turbocharger components to cool down maximum ...

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Page 35: ...ation The turbocharger is normally lubricated with oil from the engine oil circuit NOTICE With regard to the oil supply please observe the engine builder s speci fications for lubricating oil selection oil change intervals oil filtration oil pressure and oil temperature Oil filtration Filtration of the lubricating oil using a filter mesh size 0 034 mm is ade quate for TPL67 C turbochargers and a m...

Page 36: ...tion on the turbocharger are listed below Status for operation Oil pressure in front of the turbo charger bar Permissible for normal operation 1 3 2 5 Permissible during engine warm up 1 3 5 0 Temporarily permissible 1h alarm 1 1 1 3 Not permissible emergency stop 0 0 1 1 Permissible during pre and post lubrication engine stopped 0 2 2 5 NOTICE Oil orifice To make sure these oil pressures are obta...

Page 37: ...ubricating oil temperature at the outlet The oil temperature at the outlet is mainly dependant on Lubricating oil temperature and pressure at the oil inlet Engine load and turbocharger speed Exhaust gas temperature The maximum admissible oil temperature at the outlet is listed in the fol lowing table The specified oil outlet temperature is to be considered as alarm value for the turbocharger opera...

Page 38: ... filter for cleanliness before commissioning CAUTION Contaminated oil Particles of dirt and solid matter in the oil can cause serious damage to the machine or property During initial commissioning and after all service work the complete lubricating system must be flushed thoroughly with warm oil When running in the engine and after all service work on the lubricat ing system special running in fil...

Page 39: ...mperature in front of and behind turbine Measure air temperature in front of and behind compressor The measured values must be compared with the values in the ac ceptance test report while taking different operating conditions into ac count NOTICE Lubricants and pastes used during assembly of the turbocharger liquefy or vaporise and might escape as an oily liquid in the first few hours after commi...

Page 40: ... duct before gas inlet and after gas outlet Inspect exhaust gas duct line in front of and after turbine for any combustion deposits foreign matter or residual water Clean and re move Inspect air supply line or filter silencer for any foreign matter Clean and remove Start up turbocharger oil circulation system at engine end Prepare turbocharger for operation as instructed in section Inspection work...

Page 41: ...the turbocharger The highest sound pressure level of emissions1 reaches a maximum of 105 dB A near the filter silencer and over the entire speed range The following prerequisites must be fulfilled on the turbocharger in order to observe this limit value Fitted air inlet system All standard noise reducing measures have been taken2 The bellows at the air outlet have been perfectly insulated acoustic...

Page 42: ...ge 40 Copyright 2016 ABB All rights reserved April 2016 HZTL2488_EN Revision C Suggestion for noise insulation of the bellows 01 Compressor casing 04 Insulation pads 02 Bellows 05 Insulation mat at least 15 mm 03 Charge air duct scavenging air line 06 Sheet metal cover ...

Page 43: ...als CAUTION Shortened service intervals Despite observance of the service intervals unusual loads such as several start stops a day harsh environmental factors poor fuel quality or heavy installation vibration can lead to premature machine damage A shortened service interval must be arranged with ABB Turbo Sys tems NOTICE Service inspection after 5 years To prevent age and stoppage related machine...

Page 44: ... manufacturer s engine logbook Engine performance and speed Air intake temperature Exhaust gas temperature in front of and behind the turbine Pressure of charge air Pressure drop in charge air cooler Lubricating oil pressure and lubricating oil temperature Air temperature behind compressor and charge air cooler Turbocharger speed Pressure loss in air filter Servicing work according to the engine m...

Page 45: ...ing and blow air through oil ports Clean nozzle ring and check for cracks and erosion Inspect and assess bearing parts and rotor Service work every 24000 36000 hours The replacement of bearing parts as well as the inspection and assess ment of the rotor must be carried out by an ABB Turbocharging Service Station Disassemble turbocharger Measure clearances Clean the turbine and compressor wheels an...

Page 46: ...mponents and bearing parts are extremely dependent upon system specific operating conditions see Influencing parameters When the specified periodic inspections are carried out the individual components are inspected for wear and tear and replaced if necessary In this way trouble free operation is ensured The following parameters influence the replacement intervals for turbo charger components Para...

Page 47: ...ng 50000 100000 25000 50000 Gas outlet casing 50000 100000 35000 100000 Nozzle ring 35000 50000 25000 50000 Turbine diffuser cover ring 35000 50000 25000 50000 Other casings 100000 100000 Axial bearing components 24000 36000 24000 36000 Radial bearing components 24000 36000 24000 36000 Turbine blades due to wear 12000 Rotor components See the data on the rating plate GAS Gas Engine MDO Marine Dies...

Page 48: ...eed measuring system permits continuous monitoring of the turbo charger speed CAUTION Do not use cables as a climbing aid If you pull the speed measurement cables too hard contacts can be pulled out Do not tension the speed measurement cables Part number Description 42047 Screw plug 86505 Speed sensor 86515 Cable connector for 86505 86526 F I converter 86528 Tachometer 4 4 ...

Page 49: ...ed the following steps must be carried out Reduce engine performance immediately until the highest turbo charger speed no longer exceeds 70 of nBmax If the engine cannot be stopped continue to run at this reduced engine performance or turbocharger speed If the turbocharger surges continuously engine performance must be reduced further Measure the temperatures in the air and gas lines to and from t...

Page 50: ...dopted to fit it Engine and turbocharger are not running The turbocharger lubricating system is switched off Remove screw plug 42047 from bearing casing NOTICE Part position The position of the screw plug for measuring the speed is marked n on the bearing casing Screw in speed sensor 86505 as far as it will go and tighten to torque specified in table See chapter Table of tightening torques Connect...

Page 51: ...n stop the engine Switch off the lubricating oil supply to the turbocharger Disconnect the cable connector from the speed sensor Screw out defective speed sensor Screw in a new speed sensor up to the limit block Observe the tightening torque see the table of tightening torques in the chapter entitled Disassembly and assembly NOTICE Sealing the speed sensor The speed sensor is designed with a seali...

Page 52: ...ABB All rights reserved April 2016 HZTL2488_EN Revision C Stopping the engine 4 5 CAUTION Stopping the engine Heat in the turbocharger must be dissipated by the further circulating lubricating oil Allow the engine to continue running at idling speed for a further 10 minutes before stopping 4 5 ...

Page 53: ...visual checks and clean ing to ensure that the turbocharger and its attached units function trouble free The external condition and how dirty the cleaning points specified in this chapter are must be established by visual checks at the specified intervals The safety precautions must be observed during all maintenance and servicing work The cleaning points described in the following are Filter sile...

Page 54: ...6 HZTL2488_EN Revision C Cleaning the filter silencer 5 2 Filter silencer and connecting rod 81265 Filter ring if provided 81136 Absorption segment 81269 Connecting rods 81137 Sheet metal covering 81266 Cover grid 81135 Filter silencer body 81272 Screwdriver 81273 Lock nut E Insert unit absorption segment sheet metal covering 5 2 5 2 1 ...

Page 55: ...n air is Clean filter strip every 500 hours of service or more frequently if necessary Unscrew and remove lock nuts 81273 Unscrew and remove screws 81272 for connecting rods 81269 Remove connecting rods 81269 Carefully remove cover grids 81266 Pull out insert units E bend open sheet metal coverings 81137 and then remove absorption segments 81136 Clean the absorption segments 81136 During cleaning ...

Page 56: ...tion Push connecting rods 81269 through lugs of cover grids 81266 CAUTION If the connecting rods 81269 are not correctly positioned in their re cesses on the filter silencer unit 81135 the cover grid 81266 can twist and shift There is then a risk of foreign matter and contamination getting into the compressor Join connecting rods 81269 using screws 81272 When tightening the screws 81272 ensure tha...

Page 57: ... TPL67 C TPL71 C Maintenance 5 Cleaning the filter silencer 5 2 Page 55 Copyright 2016 ABB All rights reserved April 2016 HZTL2488_EN Revision C Lock nut Tightening torque Nm 81273 40 Fit filter strip 81265 If provided ...

Page 58: ... or dust are in the intake air Consequences of contamination Impaired compressor efficiency Higher exhaust gas temperatures Increased fuel consumption Increased rotor unbalance Periodic cleaning of the compressor during operation prevents or delays a severe increase of the contamination It does not however replace the regular service work during which the turbocharger is completely disman tled and...

Page 59: ...injection pipe fitted in the filter silenc er or the suction branch The water does not act as a solvent but the dirt deposit is removed by the mechanical impact of the droplets This is a very suitable process provid ed that the degree of contamination is not too high CAUTION Corrosion and deposits when cleaning Damage and impairment of turbocharger parts due to salt water and cooling water additiv...

Page 60: ...inity of the turbo charger during compressor cleaning Compressor cleaning must be activated from the engine control pan el Compressor wet cleaning operation with XC2 Trigger water injection according to the specifications of the en ginebuilder The specified water pressure upstream of the connection to the turbo charger must be maintained Operate engine for at least five additional minutes after cl...

Page 61: ...is clean ing process is faster and the risk of turbocharger surging is reduced Compressor wet cleaning procedure with XC3 It is mandatory to fulfil the operating condition prerequisites before cleaning compressors with XC3 Remove the sealing plug X Fill the vessel with the required volume of clean water see the Table of cleaning parameters Screw in the sealing plug X Push the valve activator Y aga...

Page 62: ...not satisfactory it may be repeated up to two times If the cleaning results are still not satisfactory after three attempts and the engine values are also unsatisfactory we recommend that you have the turbocharger inspected and cleaned by an official ABB Turbocharg ing Service Station Cleaning parameters per turbocharger compressor Product Engine load Contents of water vessel dm3 TPL67 C 71 C 50 8...

Page 63: ...regular and correctly performed cleaning is important in order to remove the de posits that have formed Contaminated turbine components can cause a slight increase in charging pressure because of narrowing of the turbine cross section The contami nation causes a drop in turbine efficiency and the engine temperatures downstream of the cylinder can increase The engine performance must therefore be r...

Page 64: ...ater and cooling water additives Don t use salt water for cleaning but only clean fresh water Components at the turbine end are not cleaned until the engine has been started or the engine load reduced The exhaust gas temperature must not exceed the value specified in the respective cleaning instructions see section Prerequisites 63 CAUTION Exhaust gas temperature stabilising and drying time Drasti...

Page 65: ...f turbocharger surging is reduced We recommend finding the most suitable method by performing trials Recommended operating state for turbine wet cleaning The following operating state and prerequisites have been tested and ap proved by ABB Turbo Systems for the cleaning process The engine has just been started or the engine load has been reduced as far as possible best cleaning is achieved at a lo...

Page 66: ...eter Wet cleaning procedure for turbine during operation Meet prerequisites and operating condition requirements without fail before cleaning Make sure water supply 1 is connected turned on and guaranteed Open drain pipe 8 9 if provided Switch over 3 way valve 4 from scavenging air mode to water supply NOTICE Set the required volume of water on the flow meter as shown in the ta ble in the followin...

Page 67: ...t be installed and open during the cleaning process If a drainage system is not provided the injected volume of water can be controlled by a flow meter in the water supply The maximum volume of water allowed in individual cases must be determined together with an ABB Turbocharging service station The influence of the cleaning water on peripheral equipment such as a boil er must be clarified by the...

Page 68: ...t 2016 ABB All rights reserved April 2016 HZTL2488_EN Revision C Wet cleaning parameters for turbine and nozzle ring Product Maximum tem perature at start of cleaning pro cess TTI C Injection time t i min Water flow rate per turbocharger at pWater 3 bar MW l min TPL67 C 430 10 18 TPL71 C 24 Table of cleaning parame ters ...

Page 69: ...char ger Rotor unbalance Contact an ABB Turbocharging Service Station Damaged turbine or compressor Damaged bearing Rubbing of rotating parts Normal behaviour no malfunction Turbochar ger Minor uniform wear around the periphery of rotor components caused by slight local rubbing of adjacent components is permis sible The compressor blades and turbine blades are then short ened somewhat Certain tole...

Page 70: ...d or periodic surging Possible damage to components such as the compressor wheel tur bine blades bearings and filter silencer Have the cause clarified immediately by an ABB Turbocharging ser vice station and rectified Have components inspected for damage and if necessary replaced by an ABB Turbocharging service station Sporadic surge blows Surging of the turbocharger can occur during certain opera...

Page 71: ...Turbochar ger Rotor axial clearance too large Contact an ABB Turbocharging Service Station Reduction in speed Possible causes Elimination Engine Defects of connected cylinders when pulse charging Contact the enginebuilder Turbochar ger Heavy contamination of the tur bine Clean it Damaged rotor components or bearing Contact an ABB Turbocharging Service Station Pipes Defects such as leaks in the exh...

Page 72: ...r it or contact the manufac turer Turbocharger Air starvation for example filter silencer clogged with dirt Clean it Compressor turbine conta minated Exhaust counterpressure too high Clean or repair the boiler or ex haust silencer Damaged or eroded turbine Contact an ABB Turbocharging Service Station Charge air cooler Cooler contaminated Clean it Cooling water volume too low Top up the water Entry...

Page 73: ...g Replace the manometer Line to manometer leaking Repair the leak Contaminated filter silencer causing excessive loss of pres sure Clean it Compressor turbine contami nated Damaged compressor turbine Contact an ABB Turbocharging Service Station Exhaust counterpressure too high Clean or repair the boiler or ex haust silencer Charge air pressure too high Engine performance and engine speed unchanged...

Page 74: ...ing run down Possible causes Elimination Turbochar ger Turbocharger contaminated Clean it Damaged bearing Contact an ABB Turbocharging Service Station Rubbing rotor Foreign object in turbocharger Run down time too short Possible causes Elimination Turbochar ger Turbocharger contaminated Clean it Damaged bearing Contact an ABB Turbocharging Service Station Rubbing rotor Foreign object in turbocharg...

Page 75: ... cause problems for the evaluation electronics This problem is eliminated by removing the gasket Defective sensor Contact ABB Turbocharging service station Measured speeds too high Dirty sensor tip The sensor tip is magnetic and can thus at tract metal particles As a result the dis tance to the auxiliary bearing decreases which can lead to amplification of the noise component and consequently to f...

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Page 77: ...Revision C Removal and installation Turbocharger weights 7 1 Lifting gear with a sufficient load limit must be used for removing and in stalling the turbocharger The following weight specification is the heaviest possibility This guide value can differ from data on the rating plate de pending on the specification TPL67 C TPL71 C 1330 2040 7 7 1 Weights kg ...

Page 78: ... orifice plates that are specified for the turbocharger have been installed in the two oil inlet channels Check correct installation of oil orifice plates Use the two suspension eyes on the bearing casing observe the marking on the insulation The lifting gear around the gas inlet casing serves to align the turbocharger horizontally Remove the insulation shell S from the bearing casing and possibly...

Page 79: ...ce a sling around the bearing casing Loosen the fixing screws at the foot Lift the turbocharger off the engine and set it down to one side WARNING Beware of tilting If support for the turbocharger is not provided or is inadequate the tur bocharger could tip over during installation or removal and cause a se rious or even fatal injury Support the turbocharger at a suitable point If possible secure ...

Page 80: ...the cartridge group the bearing casing or the turbocharger is fitted to the engine it must be en sured that the orifice plates that are specified for the turbocharger have been installed in the two oil inlet channels Check correct installation of oil orifice plates Fit the turbocharger to the engine Tighten the fixing screws at the foot in accordance with the engine builder s instructions Fasten t...

Page 81: ...disassembling the turbocharger Identifying assembly devices Not all assembly devices are marked with a part number They can be identified using the tool list This list is enclosed in the toolbox WARNING Maintaining assembly devices Assembly devices must be checked for damage before and after use Visually check for corrosion cracks deformation and wear Don t use damaged assembly devices but replace...

Page 82: ...ically perfect condition and has sufficient load capacity Make sure the load is suspended properly on the crane hook Do not let anyone stand beneath a suspended load Wear safety gloves against mechanical risks Wear safety helmet Definition of terms Suspension point Defined load carrying point on a component or an assembly blind hole thread eye lug Assembly device Devices mounted on the turbocharge...

Page 83: ...ividual parts or assemblies are guides round ed off to the next highest value Description TPL67 C TPL71 C 1 Filter silencer 130 180 2 Radial air suction branch 50 70 3 Compressor casing 180 260 4 Wall insert 40 65 5 Diffuser 19 35 6 Cartridge group 290 460 7 Turbine diffuser 40 60 8 Nozzle ring 10 13 9 Radial gas inlet casing 110 150 10 Segment 7 12 11 Axial gas inlet casing 65 80 8 2 Assemblies W...

Page 84: ...e 82 Copyright 2016 ABB All rights reserved April 2016 HZTL2488_EN Revision C Complete compressor casing TPL67 C TPL71 C 240 360 NOTICE The total weight of the complete compressor casing is an addition of the weights of the compressor casing the diffuser and the wall insert Weight kg ...

Page 85: ...n accordance with the engine builder s instruc tions Dismantle the insulation where necessary Pass a lifting gear around the air suction branch It is permissible to pass the lifting gear through holes possibly provided in the ribs to im prove stability Unscrew the nuts 72027 and remove them together with the washers 72018 Remove the air suction branch and set it down to one side Fit the air suctio...

Page 86: ...ed April 2016 HZTL2488_EN Revision C Remove insulation where necessary Pass lifting gear through rib on filter silencer Pass lifting gear through lugs on back Unscrew nuts 72027 and remove them together with washers 72018 Remove filter silencer and it set down to one side Install filter silencer in reverse order Removing filter silencer Installing the filter silencer ...

Page 87: ...jury Wear safety gloves Wear safety gloves against mechanical risks The axial clearance A must be measured before removing and after fit ting the cartridge group Measure and note the axial clearance A TPL67 C TPL71 C 0 31 0 49 0 33 0 50 CAUTION Clearances outside the tolerance Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts Have th...

Page 88: ...arks Layout and functioning Disconnect the oil lines in accordance with the engine builder s instruc tions CAUTION Oil orifice plates An orifice plate for adjusting the oil pressure is fitted in each of the two oil inlet channels in the bearing casing When the cartridge group the bearing casing or the turbocharger is fitted to the engine it must be en sured that the orifice plates that are specifi...

Page 89: ...ion C Remove three studs 72029 at top Attach lifting device 90190 to compressor casing 72000 then fas ten and secure it to crane using lifting gear Loosen and remove the nuts 61037 Uniformly press off compressor casing 72000 using three press off nuts 61090 fitted on bearing casing side Slightly lift compressor casing 72000 and withdraw it Remove the O ring 42012 ...

Page 90: ...ogether with wall insert and diffuser and set them down with surface F on underlay WARNING Make sure that the underlay does not shift Allow compressor casing to rest only on surface F Check the underlay and adjust it if necessary Remove the screws 72002 Remove diffuser 79000 using swivel lifting eyes 90235 Remove wall insert 77000 using swivel lifting eyes 90235 Remove O ring 77005 from wall inser...

Page 91: ... provided for this purpose Unscrew the three screws 61059 and remove them together with the Verbus Ripp washers 61058 Uniformly press off the cartridge group using the press off screws 90900 in the holes provided CAUTION If the blades have insufficient or no clearance between the rotor and the casing this can lead to damage to the blades and the casing Turn rotor to check that blades do not rub ag...

Page 92: ...2016 HZTL2488_EN Revision C Dismantling and installing the turbine diffuser and nozzle ring 8 6 Put clamp 90921 over stud 61036 until it rests on inner radius of gas outlet casing Pass extension A of torque spanner B through hole in clamp and only loosen screws 61056 one after other Do not yet remove the screws 61056 and Verbus Ripp washers 61057 8 6 Releasing the turbine diffuser ...

Page 93: ... over guide studs 90320 and studs 61036 To secure the work screw nuts 61037 onto start of stud threads 61036 Remove the remaining screws 61056 and Verbus Ripp washers 61057 Press the turbine diffuser 63000 free using the press off screws 90901 and pull it out it until the clamp 90921 is touching the nut 61037 Loop the lifting gear around the turbine diffuser 63000 and secure it to a crane Remove t...

Page 94: ... removed the nozzle ring 56001 is only clamped lightly with the gas outlet casing By pulling forward the nozzle ring 56001 is released and can drop down Pull nozzle ring 56001 forward and remove Installing the turbine diffuser and nozzle ring Install the nozzle ring and turbine diffuser in the reverse order of re moval Coat the screw threads with high temperature grease Align nozzle ring with hole...

Page 95: ... Oil orifice plates An orifice plate for adjusting the oil pressure is fitted in each of the two oil inlet channels in the bearing casing When the cartridge group the bearing casing or the turbocharger is fitted to the engine it must be en sured that the orifice plates that are specified for the turbocharger have been installed in the two oil inlet channels Check correct installation of oil orific...

Page 96: ... the bearing cas ing provided for this purpose Remove supports 90450 and carefully insert cartridge group CAUTION If the rotor blades have insufficient or no clearance the blades and cas ing could be damaged Turn rotor to check that blades do not rub against turbine diffuser Uniformly tighten the three screws 61059 with Verbus Ripp wash ers 61058 Remove the lifting gear Screw in the speed sensor 8...

Page 97: ...ed April 2016 HZTL2488_EN Revision C Fit the O ring 77005 to the wall insert 77000 Fit the swivel lifting eyes 90235 and attach lifting gear Align the wall insert 77000 using the centering screw 90187 and fit it Put the diffuser 79000 in place using the swivel lifting eyes 90235 Remove the swivel lifting eyes 90235 Fit the screws 72002 ...

Page 98: ...g device 90190 and turn com pressor casing 72000 By hand screw three press off nuts 61090 onto bearing casing studs equally spaced around circumference and up to end of thread Push compressor casing 72000 fully onto cartridge group and fasten it using nuts 61037 Secure three press off nuts 61090 against compressor casing 72000 by tightening them to specified torque See chapter Table of tightening ...

Page 99: ...e section on axial clearance CAUTION If the axial clearance A is out of tolerance an ABB Turbocharger ser vice station must be contacted Connect oil lines and all air lines in accordance with engine builder s instructions Version with compressor wheel cooling system Fit the air supply line Also see the chapter Preliminary remarks Layout and functioning Fit the filter silencer or air suction branch...

Page 100: ...1050 may only be used once Provide a new spiral wound gasket 61050 Disassembly Remove the insulation from the gas inlet casing 51001 and discon nect the cleaning pipe if provided Secure the gas inlet casing using a lifting gear CAUTION When looping the rope around the casing make sure that no cleaning pipes are crushed or damaged Do not under any circumstances fasten the lifting gear to the cleani...

Page 101: ...safety measure Loosen and remove remaining screws 61044 and segments 51012 Remove two screws 61044 in lower section Fit two guide studs 90320 as a safety measure Remove remaining screws 61044 Pull gas inlet casing complete with nozzle ring away from gas outlet casing until nozzle ring can be lifted away Remove gas inlet casing and put it down CAUTION Use suitable underlays when putting down gas in...

Page 102: ...rom oil and grease Fix a new spiral wound gasket 61050 using a little instant adhesive for example Loctite 454 gel applied at three equally spaced points in groove Fit nozzle ring to gas inlet casing and fix it Fit gas inlet casing Use guide studs 90320 as a centering aid and remove them after wards Brush screw threads 61044 with high temperature grease Position segments 51012 using screws 61044 M...

Page 103: ...ng sequence The screw positioning numbers must be marked on the component This enables simple and efficient tightening Tightening TPL67 C TPL71 C Step 1 Screw in all screws by hand Step 2 40 60 Step 3 80 130 Tightening TPL67 C TPL71 C Step 1 Screw in all screws by hand Step 3 80 130 Beginning with screw 1 tighten all screws in a clockwise direction us ing tightening torque from step 3 Remove lifti...

Page 104: ...ation Manual TPL67 C TPL71 C Disassembly and assembly 8 Table of tightening torques 8 9 Page 102 Copyright 2016 ABB All rights reserved April 2016 HZTL2488_EN Revision C Table of tightening torques 8 9 8 9 ...

Page 105: ...n C Part number TPL67 C TPL71 C 1 82005 M16x1 5 45 M16x1 5 45 3 72002 M10 50 M12 80 4 72027 with washer M14 95 M16 125 5 72029 with washer M14 30 M16 30 6 61037 M16 110 M18 160 6a 61090 M16 10 M18 15 7 61036 M16 30 M18 40 8 61059 M16 200 M18 280 9 42059 M12 80 M16 180 17 61044 M12 80 M14 130 21 61056 M12 105 M14 130 29 86505 M18x1 5 150 M18x1 5 150 Tightening torques Nm ...

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Page 107: ...rm and depending on the situation stop the engine Seal oil leaks Soak up oil and dispose of in an environmentally compatible manner Wear safety gloves against thermal risks CAUTION Directives for taking out of operation Serious damage to engine or property can be caused by non compliance with the directives for locking blanking off the turbocharger on the engine Follow the directives of the engine...

Page 108: ...This is sometimes requested by customers As operation with a locked rotor is only brief and the loads are low in these cases subsequent removal of the rotor is not necessary CAUTION During operation of the engine with a blocked turbocharger the lubricat ing oil system must remain connected to this turbocharger also and be turned on if the gas inlet cannot be blocked See section Further measures an...

Page 109: ...r wheel and tighten to values shown in Table of tightening torques CAUTION Do not remove any balancing screws from compressor wheel Use only unoccupied threaded holes to fit lifting spigot Position assembly disassembly device 90020 over studs 72026 and locking flange 94003 Turn compressor wheel so that locking flange hexagon aligns with hexagon in assembly disassembly device 90020 Secure assembly ...

Page 110: ... and the air duct on the engine side must be closed off If this is not done the undamaged turbocharger can race under no load and run at overspeed Depending on the engine turbocharging system more or less powerful pulses from the exhaust gas system act on the locked rotor The locking device is then heavily stressed particularly in the case of pulse charging turbine casing with more than one gas in...

Page 111: ...ate material General structural steel in accordance with DIN EN 10025 2 must be manufactured in house according to the drawing Product B1 B2 B3 B4 B5 B6 B7 B8 TPL67 C 13 325 30 30 8 10 6 70 TPL71 C 13 385 30 30 8 10 6 84 Product Ø 1 Ø 2 Ø 3 Ø 4 Ø 5 min Ø 6 min TPL67 C 616 694 660 16 22 15 TPL71 C 726 818 779 18 25 15 Product 1 2 3 TPL67 C 4 x 90 37 5 24 x 15 TPL71 C 4 x 90 37 5 24 x 15 9 3 Cover p...

Page 112: ...t of operation at short notice 9 Fit cover plate 9 3 Page 110 Copyright 2016 ABB All rights reserved April 2016 HZTL2488_EN Revision C NOTICE Carry out the work as described in the chapter Disassembly and As sembly Removing the cartridge group ...

Page 113: ...Fit cover plate 9 3 Page 111 Copyright 2016 ABB All rights reserved April 2016 HZTL2488_EN Revision C Close opening in gas outlet casing using cover plate Fasten cover plate using spacer sleeves and nuts 61037 CAUTION Shut off the supply of lubricating oil to the turbocharger ...

Page 114: ... builder s instructions 4 stroke engine with several turbochargers No further measures are necessary on engines with separate air and ex haust gas receivers The engine can be operated as a naturally aspirated engine according to the engine builder s instructions The air line must be closed off at the engine end because the undamaged turbochargers build up a receiver pressure CAUTION The engine can...

Page 115: ...urbocharger Shut off compressor casing outlet gas inlet and gas outlet by fitting cover plates NOTICE In this respect refer to the engine manufacturer s instructions Bypass the turbocharger 9 5 CAUTION Shut off the lubricating oil supply to the turbocharger This applies to engines with one turbocharger only The connections are ready and pipes for the bypass are available Fit bypass around turbocha...

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Page 117: ... of operation and this is circulated by the prelubrication pump no measures have to be taken Any remaining old engine oil will thus be flushed away and the bearing sections largely protected against corrosion Mothballing measures If the total acid number TAN is greater than 2 mg KOH g the following mothballing measures are necessary after taking an engine out of opera tion Remove turbocharger Roto...

Page 118: ... out of operation for up to 12 months under Moth balling measures for the measures always necessary when mothballing turbocharger parts If the turbocharger remains mounted on the engine refer to the section Taking out of operation for up to 12 months under Rotating the rotor in stack draught If the entire turbocharger is removed or if the turbocharger is re assembled next to the engine using the i...

Page 119: ...ade of leather Wear safety goggles Wear a respiratory mask to protect against particles Wear safety gloves against mechanical risks Disposal must be environmentally compatible professional and in com pliance with locally applicable regulations The turbocharger consists largely of metal cast iron materials steel nickel steel alloys aluminium and bearing brass Further components are Non metallic mat...

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Page 121: ...urbocharging Service Station CAUTION Storage of spare parts All spare parts ordered with the turbocharger must be kept complete and ready for use Parts showing signs of rust should be carefully cleaned and greased Dispose of replaced and unusable parts in a professional and envi ronmentally compatible way Required customer spare part set 97070 The customer spare part set 97070 is required for the ...

Page 122: ...ure of the turbine cleaning system Work on turbine cleaning system should be carried out only by an ABB Turbocharging service station Quantity Description Part number 6 Locking plate 51255 3 Gasket 52200 2 Hexagon head screw 52204 2 Hexagon head screw 52205 3 Nozzle 52208 2 Hexagon head screw 52257 Quantity Description Part number 4 Locking plate 51255 3 Gasket 52200 2 Hexagon head screw 52204 2 H...

Page 124: ...Manual TPL67 C TPL71 C Spare parts 12 View of turbocharger with part numbers 12 2 Page 122 Copyright 2016 ABB All rights reserved April 2016 HZTL2488_EN Revision C View of turbocharger with part numbers 12 2 12 2 ...

Page 125: ...set Hexagon nut 61044 Hexagon head screw 61050 if provided Gasket 61056 in customer spare part set Hexagon head screw 61057 in customer spare part set Verbus Ripp Washer 61058 in customer spare part set Verbus Ripp Washer 61059 in customer spare part set Hexagon head screw 63000 Turbine diffuser 68001 Foot at compressor end 68002 Foot at turbine end 68003 Slide plate 68006 Cup spring 68007 Bush 72...

Page 126: ...n C View of turbine cleaning system with part numbers optional 12 3 Axial gas inlet casing Part number Description 51229 Cleaning pipe 52249 Holder complete 51255 in spare parts set Locking plate 52200 in spare part set Gasket 52204 in spare part set Hexagon head screw 52205 in spare part set Hexagon head screw 52208 in spare part set Nozzle 52257 in spare part set Hexagon head screw 12 3 ...

Page 127: ...9 Cleaning pipe 52249 Holder complete 51255 in spare parts set Locking plate 52200 in spare part set Gasket 52204 in spare part set Hexagon head screw 52205 in spare part set Hexagon head screw 52208 in spare part set Nozzle 52209 in spare part set Nozzle 52210 in spare part set Nozzle 52213 in spare part set Locking plate 52219 in spare part set Hollow screw 52257 in spare part set Hexagon head s...

Page 128: ...ABB Turbo Systems AG Bruggerstrasse 71a CH 5400 Baden Switzerland ABB ...

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