ABB HT562838 Operation Manual Download Page 1

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Operation Manual

Turbocharging

ABB Turbo Systems Ltd

ABB Turbo Systems Ltd
CH 5401 Baden

Type

TPL65-A33

HT562838

Mmax

503

Mmax

600

Bmax

486

Bmax

600

1/s

°C

01230

Year

2013

made in Switzerland

Application according to

the Operation Manual

HZTL2498 English

TPL65-A33

Original Operation Manual

Summary of Contents for HT562838

Page 1: ...ABB Turbo Systems Ltd CH 5401 Baden Type TPL65 A33 HT562838 nMmax 503 t Mmax 600 nBmax 486 t Bmax 600 1 s C 01230 35 50 50 Year 2013 made in Switzerland Application according to the Operation Manual kg HZTL2498 English TPL65 A33 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: ...r sales service 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 Commissioning after taking out ...

Page 4: ...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 8 Turbine end removal fitt...

Page 5: ...ing the engine 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 the turbocharger with part numbers 12 3 View of cartridge group with part numbers TPL65 A32 A33 A36 12 4 View of cartridge group with part numbers TPL69 A32 A33 12 5 View of turbine cleaning system with part numbers optional Copyright 2014 ABB All ri...

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Page 7: ... intended It provides important information in order that the turbocharger can be operated safely correctly and efficiently This Operation Manual complements and expands existing national regulations concerning work safety and accident prevention Target group This Operation Manual is intended for engineers and qualified mechanics who are responsible for operating the engine and the turbocharger in...

Page 8: ...L2498_EN Revision A Layout and function 1 2 1 Filter silencer 8 Nozzle ring 2 Radial plain bearing 9 Turbine wheel 3 Thrust bearing 10 Bearing casing 4 Bearing bush 11 Diffuser 5 Radial plain bearing 12 Compressor wheel 6 Gas outlet casing 13 Compressor casing 7 Gas inlet casing 1 2 Copyright 2014 ABB All rights reserved ...

Page 9: ...ases escape to free air through the exhaust manifold which is connected to the gas outlet casing 6 The air which is necessary for the operation of the diesel engine and which is compressed in the turbocharger is drawn through the suction branch or the filter silencer 1 into the compressor wheel 12 It then passes through the diffusor 11 and leaves the turbocharger through the compressor casing 13 T...

Page 10: ... cooling means that after the charge air cooler at the engine end cooled compressor air is delivered to the turbocharger to cool the compressor wheel In view of the respective operating conditions it is absolutely essential that the compressor wheel is cooled in order to guarantee its reliability and replacement intervals In the case of the turbocharger version with compressor wheel cooling the co...

Page 11: ...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 personnel Use of the turbocharger as intended also in...

Page 12: ...t hazardous in the sense of the Hazardous Substances Ordinance Nevertheless the following points are to be observed 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 safety gloves against chemical risks The follo...

Page 13: ...and repacked Inspect the package for damage If the package is damaged the turbocharger or cartridge group must be inspected by an ABB Turbocharging 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 Replacement components ready for ope...

Page 14: ...n 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 engine in the event of alterations affecting safety or of corresponding operating behaviour The fault must be reported to the person or de...

Page 15: ...t on the technical design specifications of the turbocharger Moreover the active and or passive safety of the turbocharger may be compromised by the use of non original parts Note that such improper use may endanger personnel and the machine Use only original parts from ABB Turbo Systems ABB Turbo Systems accepts no liability whatsoever for any damage caused by the use of non original parts and ac...

Page 16: ...l do not apply to your turbocharger Our service stations and agencies will gladly answer your questions relating specifically to your model Accuracy of illustrations The graphics and images shown in this manual are of a general nature and are intended to assist understanding of the work steps and instructions Differences may exist in certain details Registered Trademarks Registered trademarks of e...

Page 17: ...on 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 Systems service stations...

Page 18: ...ne builder 2 Turbocharger operating limits during operation 3 Replacement interval for plain bearings in 1000 h 4 Replacement interval for compressor in 1000 h 5 Replacement interval for turbine in 1000 h 6 Part number for customer 7 Designation of special design 8 Turbocharger weight in kg 9 Turbocharger type 10 Serial number 11 Year of turbocharger construction 1 7 Operating limits Recommended r...

Page 19: ...fficial ABB Turbocharging service station nMmaxand tMmax normally apply only when running at overload 110 during trials 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 component failures Positions of the ...

Page 20: ...sion A Contact address and after sales service 1 8 Contact address ABB Turbo Systems AG Bruggerstrasse 71a CH 5401 Baden Switzerland www abb com turbocharging After sales service Official ABB Turbo Systems Service Stations A list of the service stations is available in the brochure Contact Information or online 1 8 Copyright 2014 ABB All rights reserved ...

Page 21: ...insufficient observance of the safety instructions 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 turbocharger by his personnel All instructions in this chapter must be observed to ensure safe and trouble free tur...

Page 22: ...nstructions 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 precisely Warning signs must be observed at all times CAUTI...

Page 23: ...ABB Turbo Systems 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 responsibility of the engine builder 2 5 C...

Page 24: ...ention 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 materials 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 obstacles on the floor Keep the floor equipment and the turbo...

Page 25: ...erational performance to person responsible If damage is discovered immediately shut down turbocharger and secure 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 or solvents will be used for ...

Page 26: ... 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 this manual Perform work only for...

Page 27: ...e turbocharger in accordance with instructions During maintenance work secure the rotor against unintentional rotation 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 Mechanical ha...

Page 28: ...sulation being used The temperature can become high enough so that it falls into ranges where burns are possible WARNING Risk of burning Touching hot surfaces or contact with hot operating materials can lead to serious burns Do not touch hot surfaces and heed the warning plate on the turbocharger Wear heat resistant safety gloves and protective clothing Allow the turbocharger to cool down before c...

Page 29: ...ion Observe details in the safety data sheets of the operating and auxiliary materials Observe local laws Wear safety goggles Wear safety gloves against chemical risks Wear a respiratory mask to protect against gases WARNING Risk of fire explosion Combustible or easily ignited operating and auxiliary materials can burst into flame or vapours from them can cause explosions Observe specifications in...

Page 30: ...bres from insulating materials can cause damage to health or irritations Unsuitable combustible insulating materials signify a fire hazard Use only suitable non combustible insulating materials Ensure that the work area is well ventilated Avoid stirring up dust Use tools and processes which keep dust to a minimum Remove packing materials only in the work area Take particular care when removing old...

Page 31: ...l 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 vessel WARNING Hazards from pressure vessels The operator must keep the pressure vessel in a proper condition ...

Page 32: ... 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 respective handling steps Before attaching slings allow turbocharger components to cool down maximum 8...

Page 33: ...free operation of the turbocharger Lubrication of the turbocharger is normally carried out with oil from the engine oil circuit NOTICE Regarding the oil supply follow the engine manufacturer s instructions concerning selection of lubricating oil oil change intervals oil filtration and oil pressure and temperature Oil filtration A lubricating oil filter system with a filter mesh size of 0 034 mm is...

Page 34: ...listed below Status for operation Oil pressure in front of the turbocharger 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 obtained a regulating orifice is f...

Page 35: ...rature 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 following table The specified oil outlet temperature is to be considered as alarm value for the turbocharger operation and must be moni...

Page 36: ...ious 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 all service work on the lubricating system special running in filters must be used Check oil pressure in oil supply lines TPL65 Version with compressor wheel cooling system Check whether compressor whe...

Page 37: ...ehind turbine Measure air temperature in front of and behind compressor The measured values must be compared with the values in the acceptance test report while taking different operating conditions into account 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 commissioning If oily liquid conti...

Page 38: ... after turbine for any combustion deposits foreign matter or residual water Clean and remove 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 before start up commissioning of chapter headed Start up commissioning Start up turbochar...

Page 39: ... 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 acoustically by the engine builder He is a...

Page 40: ...ns 4 1 Page 38 September 2014 HZTL2498_EN Revision A Suggestion for noise insulation of the bellows A Compressor casing D Insulation pads B Bellows E Insulation mat at least 15 mm C Charge air duct scavenging air pipe F Sheet metal cover Copyright 2014 ABB All rights reserved ...

Page 41: ...ned service intervals Despite observance of the service intervals unusual loads such as several start stops per day harsh environmental influencing factors or heavy installation vibration can lead to premature machine damage A shortened service interval must be arranged with ABB Turbo Systems NOTICE Service inspection after 5 years To prevent age and stoppage related machine damage an inspection b...

Page 42: ... 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 manufacturer s instructions Cle...

Page 43: ... 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 assessment of the rotor must be carried out by an ABB Turbocharging Service Station Disassemble turbocharger Measure clearances Clean the turbine and compressor wheels and inspect for damage Clean th...

Page 44: ...s 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 periods for turbocharger components Parameters influencing bearing parts Poor lubricating oil quality lubrication oil filter system condition of lubricating oil ...

Page 45: ...rbine 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 Diesel Oil HFO Heavy Fuel Oil NOTICE The specified values are guides and not guaranteed See Influencing parameters...

Page 46: ...the continuous monitoring of turbocharger speed Part number Description 42047 Screw plug 86505 Speed sensor 86515 Cable connector for 86505 86526 F I converter 86528 Tachometer Speed differences with multiple turbochargers per engine The speeds of all turbochargers on one engine differ only slightly from each other in normal operation 4 4 4 4 1 Copyright 2014 ABB All rights reserved ...

Page 47: ...as lines to and from the turbochargers and compare them with standard values If the engine can be stopped for a short time Inspect the air and gas lines as well as the turbocharger and eliminate any problems In any event it is recommended that you contact the nearest ABB Turbocharging Service Station Assembly If the speed sensor is not fitted on the turbocharger the following procedure must be ado...

Page 48: ...ubricating oil supply to the turbocharger Disconnect the cable connection from the speed sensor Screw out the defective speed sensor Screw in a new speed sensor up to the limit block Stay within 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 sealing lip and does not requi...

Page 49: ... 47 September 2014 HZTL2498_EN Revision A Stopping the engine 4 5 CAUTION Before the engine is shut down it must be allowed to idle for about 5 to 10 minutes so that the circulating lubricating oil can take away heat from the turbocharger bearings 4 5 Copyright 2014 ABB All rights reserved ...

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Page 51: ...o 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 silencer Compressor Turbine and n...

Page 52: ...A Cleaning the filter silencer 5 2 Filter silencer and connecting rod 81265 Filter strip if provided 81136 Absorption segment 81269 Connecting rods 81137 Cover sheet metal 81266 Cover grid 81135 Filter silencer body 81272 Screw 81273 Lock nut E Insert unit absorption segment cover sheet metal 5 2 5 2 1 Copyright 2014 ABB All rights reserved ...

Page 53: ...lter 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 Take out insert units E bend open cover sheet metal 81137 and then take out fleece segments 81136 Clean fleece segments 81136 When cleaning ensure that fleece segments 81136...

Page 54: ... original shape Put insert units E into slot guides in filter silencer body 81135 Uniformly lay cover sheet metal 81266 in correct position Push connecting rods 81269 through clips on cover sheet metal halves 81266 CAUTION If the connecting rods 81269 are not located correctly in their recesses on the filter silencer body 81135 the cover sheet metal 81266 can turn and shift There is then a risk of...

Page 55: ...ning screws 81272 ensure that connecting rods 81269 are located correctly in recesses in filter silencer body 81135 Now alternately tighten screws 81272 to following maximum torque Screw tightening torque Nm 81272 20 Screw lock nuts 81273 onto screw 81272 and tighten to following torque Lock nut tightening torque Nm 81273 40 Fit filter strip 81265 If provided Copyright 2014 ABB All rights reserved...

Page 56: ...ts on the compressor stage have a negative influence on the compressor efficiency and the charging pressure This results in higher exhaust temperatures and higher fuel consumption by the engine Dirty deposits on the compressor can also increase rotor unbalance Under no circumstances is periodic cleaning of the compressor during operation a substitute for the service work carried out when the turbo...

Page 57: ...e filter silencer or suction branch The water does not act as a solvent in the process but the deposit is removed by the mechanical impact of the drops This is a very suitable process provided that the build up of deposits is not too advanced CAUTION Corrosion and deposits when cleaning Damage and impairment of turbocharger parts due to salt water and cooling water additives Don t use salt water f...

Page 58: ...essor wet cleaning operation with XC2 Maintain water pressure before connection to turbocharger during water injection time as shown in table Cleaning parameters After cleaning wait at least 5 minutes to allow turbocharger to dry NOTICE If cleaning process is not satisfactory it may be repeated up to 2 times If the cleaning process is still not satisfactory after three attempts and the engine valu...

Page 59: ...must be fulfilled Engine load 50 85 Start cleaning cycle according to following description Wet cleaning operation with XC3 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 ...

Page 60: ... 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 Turbocharging Service Station Cleaning parameters per turbocharger compressor Product Engine load Contents of water vessel dm3 TPL65 A32 33 36 50 85...

Page 61: ...3 1 so that the melting point of the sodium vanadyl vanadate is as high as possible The dirty deposits increase with time so that regular and proper cleaning is important to remove what has accumulated The charging pressure can rise somewhat if the turbine cross section is reduced by dirty turbine components The dirty deposits cause a drop in turbine efficiency and a rise in engine temperatures af...

Page 62: ...and cooling water additives Don t use salt water for cleaning but only clean fresh water NOTICE 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 respective section Operating state prerequisites CAUTION Non observance of the specified ...

Page 63: ...ning but only clean fresh water Recommended operating state for turbine wet cleaning The following operating state and prerequisites have been tested and approved 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 load level of roughly 10 to 15 As soon as the turbine inlet temperature ...

Page 64: ...ing 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 table in the following chapter Cleaning parameters After injecting required volume of water shut off water s...

Page 65: ...l cases must be determined together with an ABB Turbocharging service station The influence of the cleaning water on peripheral equipment such as a boiler must be clarified by the operator The following must be observed where drainage of the gas outlet casing is concerned The exhaust gas temperature behind the turbocharger drops significantly when cleaning by 50 to 150 C Depending on the engine lo...

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Page 67: ... ABB Turbocharging Service Station Damaged turbine or compressor Damaged bearing Rubbing of rotating parts Normal behaviour no malfunction Turbocharger Minor uniform wear around the periphery of rotor components caused by slight local rubbing of adjacent components is permissible The compressor blades and turbine blades are then shortened somewhat Certain tolerances must be observed to avoid a sig...

Page 68: ...age to components such as the compressor wheel turbine blades bearings and filter silencer Have the cause clarified immediately by an ABB Turbocharging service 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 operating conditions such as when reducin...

Page 69: ...er Rotor axial clearance too large Contact ABB Turbocharging service station Drop in speed Possible causes Elimination Engine Defects of connected cylinders when pulse charging Contact engine builder Turbocharger Very dirty turbine Clean it Damaged rotor components or bearing Contact ABB Turbocharging service station Lines Defective exhaust gas lines or charge air lines such as leaky Repair them I...

Page 70: ...tact manufacturer Turbocharger Air starvation for example filter silencer clogged with dirt Clean it Dirty compressor turbine Exhaust counterpressure too high Clean or repair boiler or exhaust silencer Damaged or eroded turbine Contact ABB Turbocharging service station Charge air cooler Dirty cooler Clean it Cooling water volume too small Top up water Entry temperature of cooling water too high In...

Page 71: ...ter Line to manometer leaky Repair it Dirty filter silencer causing excessive loss of pressure Clean it Dirty compressor turbine Damaged compressor turbine Contact ABB Turbocharging service station Exhaust counterpressure too high Clean or repair boiler or exhaust silencer Charge air pressure too high Engine performance and engine speed unchanged suction condition normal Possible causes Remedy Eng...

Page 72: ...le causes Elimination Turbocharger Dirty turbocharger Clean it Damaged bearing Contact ABB Turbocharging service station Touching rotor Foreign matter in turbocharger Run down time too short Possible causes Elimination Turbocharger Dirty turbocharger Clean it Damaged bearing Contact ABB Turbocharging service station Touching rotor Foreign matter in turbocharger 6 4 Copyright 2014 ABB All rights re...

Page 73: ...ation 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 attract metal particles As a result the distance to the auxiliary bearing decreases which can lead to amplification of the noise component and consequently to faulty triggering Remove the sen...

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Page 75: ...Turbocharger weights 7 1 Lifting gear with a sufficient load limit must be used for removing and installing the turbocharger The following weight specification is the heaviest possibility This guide value can differ from data on the rating plate depending on the specification TPL65 A32 A33 A36 TPL69 A32 A33 1230 1780 7 7 1 Weights kg Copyright 2014 ABB All rights reserved ...

Page 76: ...ne builder Whenever these orifice plates are removed or if the bearing casing the cartridge group or the complete turbocharger is replaced make absolutely sure that the orifice plate with the correct diameter is fitted in the oil inlet channel in which the oil flows Re use existing orifice plate Unplug the cable connector on the speed sensor Remove the insulation at the suspension ribs TPL65 Versi...

Page 77: ... 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 turbocharger could tip over during installation or removal and cause a serious or even fatal injury Support the turbocharger at a suitable point If possible secure it using lifting gear Wear safe...

Page 78: ...d by the engine builder Whenever these orifice plates are removed or if the bearing casing the cartridge group or the complete turbocharger is replaced make absolutely sure that the orifice plate with the correct diameter is fitted in the oil inlet channel in which the oil flows Re use existing orifice plate Adapt turbocharger to suit engine Tighten fixing screws in foot in accordance with engine ...

Page 79: ... Systems recommends that the casing positions are marked before 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 def...

Page 80: ... or individual components only to lifting gear which is in technically 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 t...

Page 81: ... are guides rounded off to the next highest value Description TPL65 A32 A33 A36 TPL69 A32 A33 1 Radial air suction branch 50 70 2 Axial air suction branch 35 3 Filter silencer 130 220 4 Compressor casing 180 260 5 Wall insert 40 65 6 Diffuser 19 35 7 Cartridge group 290 360 8 Turbine diffuser 30 50 9 Nozzle ring 10 17 10 Radial gas inlet casing 50 55 8 2 Assemblies Weights kg Copyright 2014 ABB Al...

Page 82: ...014 HZTL2498_EN Revision A Complete compressor casing TPL65 A32 A33 A36 TPL69 A32 A33 Complete compressor casing 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 Copyright 2014 ABB All rights reserved ...

Page 83: ... builder s instructions 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 improve 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 suction branch in reverse order 8 3 ...

Page 84: ...ation where necessary Pass the lifting gear through the rib on the filter silencer Pass the lifting gear through the lugs on the back Unscrew the nuts 72027 and remove them together with their washers 72018 Remove the filter silencer and it set down to one side Fit the filter silencer in reverse order Removing the filter silencer Installing the filter silencer Copyright 2014 ABB All rights reserve...

Page 85: ... gloves against mechanical risks The axial clearance A must be measured before removing and after fitting the cartridge group Measure and note the axial clearance A TPL65 A32 A33 A36 TPL69 A32 A33 0 31 0 49 0 33 0 50 CAUTION Clearances out of tolerance Clearances out of tolerance and excessively worn components can be the cause of serious damage to machinery and property Have components assessed a...

Page 86: ...he required oil pressure the diameter of this orifice plate was individually adjusted by the engine builder Whenever these orifice plates are removed or if the bearing casing the cartridge group or the complete turbocharger is replaced make absolutely sure that the orifice plate with the correct diameter is fitted in the oil inlet channel in which the oil flows Re use existing orifice plate Remove...

Page 87: ...user and set them down with surface F on an underlay WARNING Tipping the compressor casing Make sure the underlay does not shift Allow the compressor casing to rest only on surface F Check the underlay and adjust it if necessary Remove the screws 72002 Remove the diffuser 79000 Remove the wall insert 77000 using swivel lifting eyes 90235 Remove the O ring 77005 from the wall insert Copyright 2014 ...

Page 88: ...o nuts 61037 Undo screw 61059 and remove together with Verbus Ripp washer 61058 Fasten separate lifting gear to each of the two ribs on the bearing casing provided for this purpose Press off cartridge group evenly 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 ...

Page 89: ...TPL69 A32 A33 Disassembly and assembly 8 Removing cartridge group 8 5 Page 87 September 2014 HZTL2498_EN Revision A Withdraw the cartridge group and fit the supports 90450 Cover the oil connections Copyright 2014 ABB All rights reserved ...

Page 90: ...g and installing the turbine diffuser and nozzle ring 8 6 CAUTION Falling nozzle ring The nozzle ring hangs only loosely on the positioning pins Before removing the turbine diffuser secure the nozzle to prevent it from falling Before disassembling the turbine diffuser if possible secure the nozzle ring against falling with a lashing strap and a wooden block 8 6 Copyright 2014 ABB All rights reserv...

Page 91: ...ge 89 September 2014 HZTL2498_EN Revision A Position clamp 90921 over stud 61036 until it lies flat against inner radius of gas outlet casing Insert extension A of torque spanner B through clamp hole and only loosen screws 61056 one after other Do not yet remove the screws 61056 and Verbus Ripp washers 61057 Copyright 2014 ABB All rights reserved ...

Page 92: ...s 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 up against the nut 61037 Loop the lifting gear around the turbine diffuser 63000 and secure it to a crane Remove nuts 61037 and clamps 90921 Fully withdraw the turbine diffuser and remove it Remove the guide studs 90320 Pull nozzle ring 56001 forw...

Page 93: ... is replaced make absolutely sure that the orifice plate with the correct diameter is fitted in the oil inlet channel in which the oil flows Re use existing orifice plate Remove cover from oil connection Secure separate lifting gear to each of two ribs on bearing casing provided for this purpose Remove supports 90450 and carefully insert cartridge group Evenly tighten the three screws 61059 togeth...

Page 94: ... not rub against turbine diffuser Remove the lifting gear Screw in the speed sensor 86505 along with the O ring 86506 and plug in the cable connector 86515 Fit the O ring 77005 to the wall insert 77000 Fit the lifting gear and the swivel lifting eye 90235 Align and fit the wall insert 77000 using the centring screw 90187 Place the diffuser 79000 in position using the swivel lifting eye 90235 Remov...

Page 95: ...00 by tightening to specified torque See chapter Table of tightening torques Remove lifting device 90190 Measure and note the axial clearance A see the section on axial clearance CAUTION Clearances out of tolerance Clearances out of tolerance and excessively worn components can be the cause of serious damage to machinery and property Have components assessed and if necessary replaced by an ABB Tur...

Page 96: ...e end Removing nozzle ring Remove insulation from gas inlet casing 51001 Loop rope around gas inlet casing and secure with lifting gear CAUTION When looping the securing line around the casing make sure that no cleaning pipes are squashed or damaged Do not fasten the lifting gear to cleaning pipes under any circumstances Remove two hexagon head screws 61044 together with Verbus Ripp washers 61043 ...

Page 97: ...nlet casing to one side use suitable underlays and take care not to damage the angles of the insulation Remove optional gasket 61050 Fitting the nozzle ring Insert optional gasket 61050 into groove in gas inlet casing 61001 Align gas inlet casing and secure using hexagon nuts 90178 on studs 90177 Insert nozzle ring 56001 and position it Brush screw threads 61044 with high temperature grease Fit th...

Page 98: ...ual TPL65 A32 A33 A36 TPL69 A32 A33 Disassembly and assembly 8 Table of tightening torques 8 9 Page 96 September 2014 HZTL2498_EN Revision A Table of tightening torques 8 9 8 9 Copyright 2014 ABB All rights reserved ...

Page 99: ...umber TPL65 A32 A33 A36 TPL69 A32 A33 1 82005 M16x1 5 45 M16x1 5 45 4 72027 with washer M14 95 M16 125 5 72029 M14 30 M16 30 6 61044 61056 61059 61071 TPL69 A32 33 M14 160 M16 260 7 61036 M12 80 M16 105 10 61037 M14 75 M16 105 11 61090 M14 5 M16 10 14 86505 M18x1 5 150 M18x1 5 150 103 72002 M10 50 M12 80 Tightening torques Nm Copyright 2014 ABB All rights reserved ...

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Page 101: ...situation shut down engine Seal leak 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 enginebuilder If the diesel engine...

Page 102: ...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 lubricating oil system must remain connected to this turbocharger also and be turned on if the gas inlet cannot be blocked See section Further measures and information for operation w...

Page 103: ...hreaded holes of compressor wheel and tighten them as specified in following Table of tightening torques CAUTION Don t remove any balancing screws from compressor wheel Use only unoccupied threaded holes to fit lifting device 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 disa...

Page 104: ... short notice 9 Locking the rotor 9 2 Page 102 September 2014 HZTL2498_EN Revision A Part number TPL65 A32 A33 A36 72027 M14 75 Nm 94007 M8 25 Nm CAUTION Make sure all components are clean and free from grease Table of tightening torques Copyright 2014 ABB All rights reserved ...

Page 105: ...ghten them as specified in the following Table of tightening torques CAUTION Don t remove any balancing screws from compressor wheel Use only unoccupied threaded holes to fit lifting device Push intermediate ring 94001 and assembly disassembly device 90020 onto locking flange 94003 in correct order As specified in following Table of tightening torques tighten intermediate ring assembly disassembly...

Page 106: ... notice 9 Locking the rotor 9 2 Page 104 September 2014 HZTL2498_EN Revision A Part number TPL69 A32 A33 72027 M16 105 Nm 94006 M6 10 Nm 94007 M6 10 Nm CAUTION Make sure all components are clean and free from grease Table of tightening torques Copyright 2014 ABB All rights reserved ...

Page 107: ...gine 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 inlet With this in mind the f...

Page 108: ... 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 TPL65 13 325 30 30 8 10 6 70 TPL69 13 385 30 30 8 10 6 84 Product Ø 1 Ø 2 Ø 3 Ø 4 Ø 5 Ø 6 TPL65 616 694 660 16 22 15 TPL69 726 818 779 18 25 15 Product α 1 α 2 α 3 TPL65 TPL69 4 x 90 37 5 24 x 15 9 3 Cover plate dimensions mm Copyright 2014 ABB All righ...

Page 109: ...33 Taking out of operation at short notice 9 Fit cover plate 9 3 Page 107 September 2014 HZTL2498_EN Revision A NOTICE Carry out the work as described in the chapter Removal and fitting Remove cartridge group Copyright 2014 ABB All rights reserved ...

Page 110: ...e 9 Fit cover plate 9 3 Page 108 September 2014 HZTL2498_EN Revision A Close off 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 Copyright 2014 ABB All rights reserved ...

Page 111: ...roke engine with several turbochargers No further measures are necessary on engines with separate air and exhaust 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 be operated according to the...

Page 112: ...or 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 turbocharger NOTICE In this respect r...

Page 113: ...tion no measures need to be taken either Residues of old engine oil are flushed away in this way and the bearing parts are largely protected against corrosion Preparations for mothballing WARNING Handling operating materials and supplies Swallowing or inhaling vapours of operating materials and supplies or contact with them may be harmful to health Do not breathe in these substances and avoid cont...

Page 114: ...be dismantled and subsequently refitted by an ABB Turbocharging Service Station Clean all parts Coat plain surfaces of steel and cast parts with anticorrosive oil Fit turbocharger completely Rotation of the rotor in the stack draught If the rotor turns as a result of the stack draught Install a blind flange between the outlet flange of the compressor casing and the charge air duct Copyright 2014 A...

Page 115: ...See the section Taking out of operation for up to 12 months under Mothballing 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 complete turbocharger is removed or if the turbocharger is refitted from its in...

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Page 117: ...ety goggles Wear a respiratory mask to protect against particles Wear safety gloves against mechanical risks Disposal must be environmentally compatible professional and in compliance 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 materials filter components...

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Page 119: ...rts can be ordered from an official ABB Turbocharging Service Station If different design versions have not been taken into consideration in this document please contact an ABB Turbocharging 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 ...

Page 120: ...agon nut 61037 1 Spiral gasket 61050 12 Hexagon head screw 61056 12 Verbus Ripp Washer 61057 3 Verbus Ripp Washer 61058 3 Hexagon head screw 61059 1 Gasket 77005 1 O ring seal speed sensor 86506 Quantity Description Part number 1 O ring 42012 1 Gasket 42041 1 Gasket 42045 15 Verbus Ripp Washer 42058 42063 61043 61057 61058 15 Hexagon head screw 42059 42064 61044 61056 61059 3 Hexagon nut 61037 1 G...

Page 121: ...TION Leaks Improper assembly of the cleaning pipe and the nozzles can lead to leaks and failure 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 2 Locking plate 51255 3 Nozzle 52208 6 Sleeve 52212 1 Locking plate 52213 6 Strain bolt 52217 6 Nut 52218 Copyright 2014 ABB All rights reser...

Page 122: ...32 A33 A36 TPL69 A32 A33 Spare parts 12 View of the turbocharger with part numbers 12 2 Page 120 September 2014 HZTL2498_EN Revision A View of the turbocharger with part numbers 12 2 12 2 Copyright 2014 ABB All rights reserved ...

Page 123: ...erbus Ripp Washer 61044 in customer spare part set Hexagon head screw 61050 only TPL65 A32 A33 Spiral 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 68000 Foot 72000 Compressor casing 72018 Washer 72027 Hexago...

Page 124: ...A32 A33 Spare parts 12 View of cartridge group with part numbers TPL65 A32 A33 A36 12 3 Page 122 September 2014 HZTL2498_EN Revision A View of cartridge group with part numbers TPL65 A32 A33 A36 12 3 12 3 Copyright 2014 ABB All rights reserved ...

Page 125: ...loating disc 32106 Axial bearing 32107 Bearing bush 42001 Bearing casing 42002 Hood 42011 O ring 42015 Sealing cover 42041 in customer spare part set Gasket 42045 in customer spare part set Gasket 42058 in customer spare part set Verbus Ripp Washer 42059 in customer spare part set Hexagon head screw 42063 Verbus Ripp Washer 42064 Hexagon head screw 43002 option with compressor wheel cooling system...

Page 126: ...L69 A32 A33 Spare parts 12 View of cartridge group with part numbers TPL69 A32 A33 12 4 Page 124 September 2014 HZTL2498_EN Revision A View of cartridge group with part numbers TPL69 A32 A33 12 4 12 4 Copyright 2014 ABB All rights reserved ...

Page 127: ... 32106 Axial bearing 32107 Bearing bush 42001 Bearing casing 42002 Hood 42011 O ring 42015 Sealing cover 42041 in customer spare part set Gasket 42045 in customer spare part set Gasket 42058 in customer spare part set Verbus Ripp Washer 42059 in customer spare part set Hexagon head screw 42063 in customer spare part set Verbus Ripp Washer 42064 in customer spare part set Hexagon head screw 42155 o...

Page 128: ...iew of turbine cleaning system with part numbers optional 12 5 Part number Description 51229 Cleaning pipe 52249 Holder complete 51255 in spare parts set Locking plate 52208 in spare parts set Nozzle 52212 in spare parts set Bush 52213 in spare parts set Locking plate 52217 in spare parts set Strain bolt 52218 in spare parts set Nut 12 5 Copyright 2014 ABB All rights reserved ...

Page 129: ...ABB Turbo Systems AG Bruggerstrasse 71a CH 5400 Baden Switzerland ABB ...

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