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Operation Manual / TPL76-C

Table of contents

HZTL2485_EN

Revision E

July 2017

Operation Manual

Preliminary remarks................................................................................................. 3

1.1

Purpose of this manual .................................................................................................. 3

1.2

Layout and function........................................................................................................ 4

1.3

Intended use..................................................................................................................... 6

1.4

Deflagration on gas engines......................................................................................... 7

1.5

Storage of new turbochargers and spare parts ....................................................... 8

1.6

Essential information................................................................................................... 10

1.7

Symbols and definitions .............................................................................................. 12

1.8

Turbocharger rating plate ........................................................................................... 13

1.9

Contact information..................................................................................................... 14

Safety....................................................................................................................... 15

2.1

Introduction ................................................................................................................... 15

2.2

CE conformity ................................................................................................................ 15

2.3

Definition of mandatory signs ................................................................................... 16

2.4

Definition of Safety instructions ............................................................................... 16

2.5

Warning plates on the turbocharger......................................................................... 17

2.6

Safe operation and maintenance............................................................................... 18

2.7

Hazards during operation and maintenance........................................................... 21

2.8

Periodic checking of the pressure vessel ................................................................. 26

2.9

Lifting loads ................................................................................................................... 26

Commissioning...................................................................................................... 28

3.1

Oil supply ........................................................................................................................ 28

3.2

Inspection work ............................................................................................................. 31

3.3

Commissioning after taking out of operation........................................................ 33

Operation ............................................................................................................... 34

4.1

Noise emissions ............................................................................................................ 34

4.2

Servicing work ............................................................................................................... 36

4.3

Replacement intervals for turbocharger components .......................................... 39

4.4

Speed measurement .................................................................................................... 41

4.5

Stopping the engine ..................................................................................................... 43

Maintenance .......................................................................................................... 45

5.1

Foreword to Maintenance .......................................................................................... 45

5.2

Cleaning the filter silencer.......................................................................................... 46

5.3

Cleaning the compressor during operation ........................................................... 49

5.4

Cleaning turbine blades and nozzle ring in operation ........................................... 55

5.5

Cleaning components mechanically......................................................................... 60

Summary of Contents for HT575928

Page 1: ... Systems Ltd CH 5401 Baden Type TPL76 C32 HT575928 nMmax 343 t Mmax 650 nBmax 326 t Bmax 620 1 s C 04070 35 50 50 Year 2017 made in Switzerland Application according to the Operation Manual kg HZTL2485 English TPL76 C32 Original Operation Manual ...

Page 2: ...Replacement intervals of components depends on the load profile turbine inlet temperature suction air temperature and turbocharger speed In case the operation conditions differs significantly from what is considered to be normal for the cur rent application it is recommended to contact ABB for a re calculation of replacement intervals Frequent load alterations high temperatures and high speed lowe...

Page 3: ...n of Safety instructions 16 2 5 Warning plates on the turbocharger 17 2 6 Safe operation and maintenance 18 2 7 Hazards during operation and maintenance 21 2 8 Periodic checking of the pressure vessel 26 2 9 Lifting loads 26 3 Commissioning 28 3 1 Oil supply 28 3 2 Inspection work 31 3 3 Commissioning after taking out of operation 33 4 Operation 34 4 1 Noise emissions 34 4 2 Servicing work 36 4 3 ...

Page 4: ...anch 84 8 4 Axial clearance 86 8 5 Removing cartridge group 87 8 6 Dismantling and installing the turbine diffuser and nozzle ring 94 8 7 Installing cartridge group 99 8 8 Dismantling and fitting nozzle ring at turbine end 108 8 9 Table of tightening torques 116 9 Taking out of operation at short notice 118 9 1 Possibilities for emergency repair 118 9 2 Locking the rotor 119 9 3 Fit cover plate 12...

Page 5: ...ms and to use it as 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 reg ulations concerning work safety and accident prevention Target group This Operation Manual is intended for engineers and qualified mechan ics who are responsible for operating the engine an...

Page 6: ...ved HZTL2485_EN Revision E July 2017 1 2 Layout and function 01Filter silencer 08Nozzle ring 02Radial plain bearing 09Turbine wheel 03Thrust bearing 10Bearing casing 04Bearing bush 11Diffuser 05Radial plain bearing 12Compressor wheel 06Gas outlet casing 13Compressor casing 07Gas inlet casing Page 4 133 ...

Page 7: ...asses 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 oil circuit The oil ...

Page 8: ...determined on the basis of information from the enginebuilder about the intended use These data are given on the rating plate ABB Turbo Systems accepts no liability and rejects all warranty claims for any non intended uses 1 Euromot The European Association of Internal Combustion Engine Manufacturers 2 Directive 94 9 EC concerning equipment and protective systems in tended for use in potentially e...

Page 9: ...ation on gas engines ABB turbochargers can tolerate a deflagration with a transient pressure increase of 12 bar ABB Turbo Systems recommends subjecting the turbocharger to a visual inspection after a deflagration event As part of the inspection the posi tion of the turbine casing and the position of the compressor casing to the bearing casing must be checked and the bearing casing must be ex amine...

Page 10: ...ts are not hazardous in the sense of the Hazardous Sub stances Ordinance Nevertheless the following points are to be ob served when handling VCIs u Ensure good room ventilation u Do not eat drink or keep food at the workplace while working with VCIs u Wear safety gloves u Clean hands and face after working with VCIs u For further information refer to www branopac com Wear safety gloves to protect ...

Page 11: ...rvice Sta tion and repacked u Inspect the package for damage If the package is damaged the tur bocharger or cartridge group must be inspected by an ABB Tur bocharging 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 compo...

Page 12: ...ng safety or of corresponding operating beha viour by stopping the engine The fault should be reported to the per son or department responsible NOTICE Any modifications additions or conversions made to the turbocharger which could impair safety require the prior approval of ABB Turbo Sys tems Original parts and safety Original parts and accessories are specially designed for the turbochar ger supp...

Page 13: ...ons The illustrations in this document are general in nature and intended for ease of understanding Differences in detail are therefore possible Storage of new turbochargers New turbochargers supplied by ABB Turbo Systems can be stored without additional safeguarding measures for a period of 6 months after the delivery date Suitable storage locations are dry rooms where the relative humidity is be...

Page 14: ...efinition 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 com plied 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 ...

Page 15: ...ed with the enginebuilder 02 Turbocharger operating limits during operation Recommended replace ment intervals for tur bocharger components 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 Further information 06 Part number for customer 07 Designation of special design 08 Turbocharger weight in kg 09...

Page 16: ...erload 110 during trials on the engine test bed These limits can also be permitted during op eration for special applications Operation above nMmax and tMmax is not per mitted Non observance of the recommended replacement intervals can increase the risk of unpredictable component failures 1 8 2 Positions of the rating plates A rating plate is attached to the turbocharger foot one on the left and o...

Page 17: ...f insufficient observance of the safety instruc tions are the consequence of unsatisfactory and improper execution of maintenance and inspection work The operating company is responsible for access to the turbocharger as well as the organisational measures that regulate the safe handling of the turbocharger by its personnel All instructions contained in this chapter must be observed for safe and t...

Page 18: ...otection 2 4 Definition of Safety instructions 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 pre cisely u Warning signs m...

Page 19: ...tes that must be observed are attached to the turbocharger The warning plates must always be present in the intended locations and must be legible 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 Page 17 133 ...

Page 20: ...rbocharger if you are under physical or mental stress u Work only with suitable tools as well as equipment and working ma terials that are in perfect condition u Electric tools must be solidly earthed and connecting cables may not be damaged u Keep the workplace clean clear away loose objects and remove obstacles on the floor u Keep the floor equipment and the turbocharger clean u Have oil binding...

Page 21: ...or changes in operational perform ance to person responsible u If damage is discovered immediately shut down turbocharger and se cure it against inadvertent or unauthorized use u 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 If cleaning agents or solvents are use...

Page 22: ... supply of oil is interrupted especially with an external oil supply u 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 u Perform only those tasks that are described in this manual u Perform work only for which training has been carried out Safety when takin...

Page 23: ...ger in accordance with instructions u 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 instruc tions due to inadequate care or as a consequence of insufficient train ing WARNING Mechanical hazards ...

Page 24: ...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 operating materials lubricating oil become hot The surface temperat ure is dependent on the effectiveness of the insulation being used The temperature can become high enough so that it falls into ranges where burns are possible WARNING ...

Page 25: ...r surfaces is compuls ory Wear safety gloves to protect against thermal hazards 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 Operating and auxiliary materials can be combustible and easily ig...

Page 26: ...nation of the ground and water due to improper disposal can lead to environmental damage u Handle operating and auxiliary materials carefully u Heed the instructions for use safety data sheets and hazard notices on the containers of the operating and auxiliary materials u Wear appropriate protective clothing u Avoid inhalation and contact with the skin u Ensure that the work space is adequately ve...

Page 27: ... in accordance with applicable local regulations Wear safety goggles Wear a respiratory mask to protect against dusts Wear safety gloves to protect against chemical hazards u Use only suitable non combustible insulating materials u Ensure that the work area is well ventilated u Wear suitable work clothing safety glasses respiratory mask u Avoid stirring up dust u Use tools and processes which keep...

Page 28: ...ating company must make sure the pressure vessels are in proper working condition and monitor them Necessary repair or main tenance work must be carried out without delay and the required safety precautions must be taken u Pressure equipment must not be operated if it has defects 2 9 Lifting loads WARNING Suspended loads Loads not suspended in compliance with regulations may lead to per sonal inju...

Page 29: ...ding u Fasten turbocharger assemblies components as described in re spective handling steps u Before attaching slings allow turbocharger components to cool down maximum 80 C u Use suitable protection at sharp edges u Completely screw in assembly fitting devices without fail so that they cannot work loose during use u Use assembly fitting devices only for applications described u Make sure removed ...

Page 30: ...rbocharger operation The turbocharger is normally lubricated with oil from the engine oil cir cuit NOTICE With regard to the oil supply please observe the engine builder s spe cifications for lubricating oil selection oil change intervals oil filtration oil pressure and oil temperature Oil filtration A lubrication oil filter system with a mesh size 0 050 mm is adequate for TPL76 C turbochargers NO...

Page 31: ...r are listed below Status for operation Oil pressure at measuring point M poil in bar Permissible for normal operation 1 3 2 5 Permissible during engine warm up 1 3 5 0 Temporarily admissible 1 h alarm 1 1 1 3 Not permissible emergency stop 0 0 1 1 Permissible during pre and post lubrica tion engine stopped 0 2 2 5 Oil orifice plate To ensure these oil pressures a regulating orifice plate is fitte...

Page 32: ...perature at 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 operation and must be monit...

Page 33: ...inated oil Particles of dirt and solid matter in the oil can cause serious damage to the machine or property u During initial commissioning and after all service work the complete lubricating system must be flushed thoroughly with warm oil u When running in the engine and after all service work on the lubricat ing system special running in filters must be used u Check oil pressure in oil supply li...

Page 34: ...perature in front of and behind turbine u Measure air temperature in front of and behind compressor The measured values must be compared with the values in the accept ance test report while taking different operating conditions into ac count NOTICE Lubricants and pastes used during assembly of the turbocharger li quefy or vaporise and might escape as an oily liquid in the first few hours after com...

Page 35: ...efore gas inlet and after gas outlet u Inspect exhaust gas duct line in front of and after turbine for any combustion deposits foreign matter or residual water Clean and re move u Inspect air supply line or filter silencer for any foreign matter Clean and remove u Start up turbocharger oil circulation system at engine end u Prepare turbocharger for operation as instructed in section Inspec tion wo...

Page 36: ...arger 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 or der 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 ally by t...

Page 37: ...ght 2017 All rights reserved HZTL2485_EN Revision E July 2017 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 35 133 ...

Page 38: ...ed service intervals Despite observance of the service intervals unusual loads such as sev eral start stops a day harsh environmental factors poor fuel quality or heavy installation vibration can lead to premature machine damage u 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 damage an inspe...

Page 39: ...er 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 If provided Air temperature behind compressor and charge air cooler Turbocharger speed Pressure loss in air filter 4 2 3 Servicing work according to the e...

Page 40: ...r through oil ports u Clean nozzle ring and check for cracks and erosion u Inspect and assess bearing parts and rotor 4 2 5 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 u Disassemble turbocharger u Measure clearances u Clean the turbine and compressor wheels a...

Page 41: ...ntervals for non rotating components 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 Influencing parameters The following parameters influence the repl...

Page 42: ... HFO Gas inlet casing 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 Recommended replace ment intervals h Rotor components See rat...

Page 43: ...ystem permits continuous monitoring of the tur bocharger speed CAUTION Do not use cables as a climbing aid If you pull the speed measurement cables too hard contacts can be pulled out u 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 Page 41 133 ...

Page 44: ...ously engine performance must be reduced further u Measure the temperatures in the air and gas lines to and from the tur bochargers and compare them with standard values If the engine can be stopped for a short time u Inspect the air and gas lines as well as the turbocharger and eliminate any problems u In any event it is recommended that you contact the nearest ABB Tur bocharging Service Station ...

Page 45: ...sor u Screw out defective speed sensor u Screw in a new speed sensor up to the limit block u Observe the tightening torque see the table of tightening torques in the chapter entitled Disassembly and assembly NOTICE Sealing of the speed sensor The speed sensor is designed with a sealing lip and does not require any additional gasket for assembly u Connect cable connector to speed sensor u Switch on...

Page 47: ... 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 spe cified intervals The safety precautions must be observed during all maintenance and servicing work The cleaning points described in the following are Filter silencer Compres...

Page 48: ... July 2017 5 2 Cleaning the filter silencer 5 2 1 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 sheetmetal covering Page 46 133 ...

Page 49: ...en sheet metal coverings 81137 and then remove absorption segments 81136 u Clean the absorption segments 81136 During cleaning ensure that the absorption segments 81136 are only cleaned with a mild jet of compressed air soft brush or a damp cloth Otherwise there is a risk of damage or deformation NOTICE Replace heavily contaminated or damaged parts with original parts from ABB Turbo Systems Fittin...

Page 50: ... There is then a risk of foreign matter and dirt getting into the compressor u Join connecting rods 81269 using screws 81272 When tightening the screws 81272 ensure that connecting rods 81269 are located correctly in recesses in filter silencer body 81135 Now tighten screws 81272 alternately until the following maximum torque is reached Screw Tightening torque Nm 81272 20 u Screw lock nuts 81273 o...

Page 51: ...nels if salt oil mist exhaust gas or dust are sucked in with the 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 any major increase in contamination It does not however replace the regular service work during which the turboch...

Page 52: ...ontamination is not too high CAUTION Corrosion and deposits when cleaning Damage and impairment of turbocharger parts due to salt water and cooling water additives u Don t use salt water for cleaning but only clean fresh water CAUTION Uncontrolled volumes of water Uncontrolled volumes of water can damage the turbocharger and the engine u Never connect the water line without the orifice specified f...

Page 53: ...ent in the vicinity of the tur bocharger during compressor cleaning u Compressor cleaning must be activated from the engine control panel Wet cleaning procedure for compressor with XC2 u Trigger water injection according to the specifications of the en ginebuilder u The specified water pressure upstream of the connection to the tur bocharger must be maintained u Operate engine for at least five ad...

Page 54: ...f despite correct settings surging of the compressor stage occurs while cleaning the compressor as a remedial measure the engine load can be reduced further while cleaning the compressor The reduction of the engine load can lead to a reduction in the effectiveness of the com pressor cleaning u To avoid a decreased engine availability the compressor stage can be cleaned at reduced engine load durin...

Page 55: ...e that has been tested and is recommended by ABB Turbo Systems the following pre requisite must be met u Engine load 50 85 u Start cleaning cycle according to following description Wet cleaning operation with XC3 Operating procedure for compressor wet cleaning with XC3 Operating the water pres sure vessel u The operating state prerequisites for compressor cleaning with XC3 must be fulfilled u Remo...

Page 56: ...urging of the compressor stage Should repeated surging of the compressor stage occur during com pressor cleaning first the cleaning parameters as well as the engine side system must be checked with regard to deviations e g an increased pressure loss in the charge air cooler and corrected if necessary If despite correct settings surging of the compressor stage occurs while cleaning the compressor a...

Page 57: ... in turbine efficiency and the engine tem peratures downstream of the cylinder can increase The engine perform ance must therefore be reduced if necessary The contamination of the turbine also causes rotor unbalance Extremely heavy contamination can lead to non permissibly high unbalance of the rotor Operating experience has shown that in spite of regular cleaning during operation it is essential ...

Page 58: ...n started or the engine load reduced The exhaust gas temperature must not exceed the value specified in the respective cleaning instructions see section PrerequisitesTPL A C Operating state prerequisites for wet cleaning turbine and nozzle ring 57 CAUTION Reduced service life of the components Failure to comply with the minimum stabilisation time before cleaning the prescribed turbine inlet temper...

Page 59: ...rating state and prerequisites have been tested and approved by ABB Turbo Systems for the cleaning process u 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 15 u As soon as the turbine inlet temperature is stable and below 430 C wait at least another 10 minutes for the charger parts to cool down u Start...

Page 60: ... guaranteed u Open drain pipe 08 09 if provided u Switch over 3 way valve 04 from scavenging air mode to water sup ply u Set the required volume of water on the flowmeter as shown in the table see table Cleaning parameters u Shut off the water supply again by switching the 3 way valve 04 to scavenging air mode after injecting the required volume of water u The injection process has been completed ...

Page 61: ...wed 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 boiler must be clarified by the operator Points to remember when cleaning The following points must be observed with regard to draining the gas outlet casing The exhaust gas temperature behind the turbocharger drops signi ficantly when ...

Page 62: ...eferably using the cleaning method de scribed in the following CAUTION Choosing cleaning tools Turbocharger components are sensitive to mechanical damage The use of needle guns or other impact tools for example damages the components Depending on the specification nozzle rings have pro tective coatings which can also be damaged u Only use soft tools such as scouring cloths brushes or wire brushes ...

Page 63: ...sheet u Comply with local legislation Wear safety goggles Wear safety gloves to protect against chemical hazards Wear a respiratory mask to protect against gases Baked on layers of contamination for example from heavy fuel oil or coked oil occur at the turbine end The following performance relevant parts can be cleaned according to the following description 56001 Nozzle ring 63000 Turbine diffuser...

Page 64: ...oup on the compressor end CAUTION Selection of the cleaning agent Cleaning agents which contain chlorine attack metals u Use only pH neutral cleaning agents which do not attack metals u Observe safety data sheet CAUTION Water and contamination in the cartridge group If water or contamination penetrates the cartridge group this can im pair the function of the turbocharger and damage parts inside th...

Page 65: ...ally in a container with fluid The cartridge group must be rotated to do this u Two cranes or chain blocks must be used for the rotating operation Suspending the chain block directly from the crane and rotating the cart ridge group is not permitted because of the risk of damage to the com pressor wheel Cartridge group with one central suspension point CAUTION Damage to compressor wheel The lifting...

Page 66: ...L2485_EN Revision E July 2017 4 When the cartridge group is horizontal secure one chain block to one of the upper push off threads using a swivel lifting eye and suspend from the second crane 5 Tighten chain block until entire cartridge group is suspended from second crane 6 Remove loop from first crane Page 64 133 ...

Page 67: ...must not touch the compressor wheel at any time dur ing rotation u Choose appropriate lifting gear length 1 Suspend cartridge group from the two side suspension points on the crane using two lifting loops or Attach two swivel lifting eyes to the side and suspend the cartridge group from the crane using two lifting loops 2 Attach third lifting loop with swivel lifting eye to thread of oil outlet fl...

Page 68: ...il entire cartridge group is suspended from first crane 6 Remove loop from second crane CAUTION Selection of the cleaning agent Cleaning agents which contain chlorine attack metals u Use only pH neutral cleaning agents which do not attack metals u Observe safety data sheet u Fill the tank with soaking liquid u Only immerse the cartridge group until all blades are covered with cleaning agent NOTICE...

Page 69: ...on may be impaired and parts in the cartridge group may be damaged u Place cartridge group on suitable wooden or metal supports u Allow the layers of contamination on the turbine to soak for at least four hours Removing contamination WARNING Health hazard due to soot particles If soot particles enter the eyes or respiratory tract this can be harmful to health u Avoid the formation of dust u Vacuum...

Page 70: ...alance This can result in bearing or turbocharger damage u Remove all traces of contamination from the turbine u After brushing off the contamination fill the tank with clean water not salt water u Submerge the turbine of the cartridge group in clean water so that loose particles of contamination detach completely u Lift the cartridge group u Dry turbine and gap between turbine and sealing cover w...

Page 71: ...r unbalance Contact an ABB Turbocharging Service Station Damaged turbine or com pressor 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 per missible The compressor blades and turbine blades are then shortened somewhat Certain tolerances must b...

Page 72: ...ing Possible damage to components such as the compressor wheel tur bine blades bearings and filter silencer u Have the cause clarified immediately by an ABB Turbocharging ser vice station and rectified u 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 condi tio...

Page 73: ...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 turbine Clean it Damaged rotor components or bearing Contact an ABB Turbocharging Service Station Pipes Defects such as leaks in the ex haust gas pipes...

Page 74: ...he manu facturer Turbocharger Air starvation for example filter silencer clogged with dirt Clean it Compressor turbine con taminated 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 temperature of c...

Page 75: ...meter Line to manometer leaking Repair the leak Contaminated filter silencer causing excessive loss of pres sure Clean it Compressor turbine contam inated Damaged compressor tur bine 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 air intake condi...

Page 76: ...ssible 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 turbocharger Page 74 133 ...

Page 77: ... for the evaluation electronics This problem is eliminated by removing the gasket Defective sensor Contact ABB Turbocharging service sta tion 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 faulty triggeri...

Page 78: ...Removal and installation 7 1 Turbocharger weight Lifting gear with a sufficient load limit must be used for removing and installing the turbocharger The following weight specification is the heaviest variant possible This standard value may deviate from the data on the rating plate depending on the specification Weight kg TPL76 C 4070 Page 76 133 ...

Page 79: ...n 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 ensured that the orifice plates that are specified for the turbocharger have been installed in the two oil inlet channels u Check correct installation of oil orifice plates Suspension dimension Distance in mm A 860 B 1210 C 800 Use the two su...

Page 80: ...e lifting gear to the suspension eyes of the bearing casing and the turbine end foot u Unplug the cable connector on the speed sensor u Unscrew the fixing screws on the feet u Lift the turbocharger off the engine and set it down to one side WARNING If the turbocharger is not sufficiently supported or not supported at all during removal and installation it may tip over and cause severe injury to pe...

Page 81: ...r the turbocharger is fitted to the engine it must be ensured that the orifice plates that are specified for the turbocharger have been installed in the two oil inlet channels u Check correct installation of oil orifice plates u Fit the turbocharger to the engine u Tighten the fixing screws on the foot NOTICE The fastening specifications for the foot fixing screws are supplied to the engine builde...

Page 82: ...n this chapter u Mark the casing position for assembly 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 u Visually check for corrosion cracks deformation and wear u Don t use damaged ...

Page 83: ... assemblies or individual components only to lifting gear which is in technically perfect condition and has suffi cient load capacity u Make sure the load is suspended properly on the crane hook u Do not let anyone stand beneath a suspended load Wear safety gloves to protect against mechanical hazards Wear safety helmet Definition of terms Suspension point Defined load attachment point on a compon...

Page 84: ... highest value Assemblies Weights kg Item Description TPL76 C 1 Filter silencer 280 2 Axial air suction branch 70 3 Radial air suction branch 120 4 Compressor casing internal part 220 5 Wall insert 220 6 Diffuser 45 7 Compressor casing external part 310 8 Cartridge group 900 9 Turbine diffuser 80 10 Nozzle ring 23 11 Radial gas inlet casing with segment connection 250 12 Segment 18 13 Radial gas i...

Page 85: ...l rights reserved HZTL2485_EN Revision E July 2017 Complete compressor casing internal part Weight kg TPL76 C 490 NOTICE The total weight of the complete internal part of the compressor casing includes the internal part of the compressor casing the diffuser and the wall insert Page 83 133 ...

Page 86: ... air suction branch u Disconnect all air lines ducts in accordance with engine builder s in structions u Remove the insulation where necessary u Loop the lifting gear around the air suction branch u Unscrew the nuts 74027 and remove them together with their wash ers 74018 u Remove the air suction branch and set it down to one side Installing the air suction branch u Install the air suction branch ...

Page 87: ...EN Revision E July 2017 Removing filter silencer u Remove insulation where necessary u Pass lifting gear through rib on filter silencer and through eyelets at rear u Unscrew nuts 74027 and remove them together with washers 74018 u Remove filter silencer and it set down to one side Fitting the filter silencer u Fit filter silencer in reverse order Page 85 133 ...

Page 88: ...y gloves Wear safety gloves to protect against mechanical hazards The axial clearance A must be measured before removing and after in stalling the cartridge group u Measure and note the axial clearance A Clearance A mm TPL76 C 0 43 0 69 CAUTION Clearances outside the tolerance Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts u Have ...

Page 89: ...r nuts 74027 complete with washers 74018 equally spaced around circumference and tighten u Remove insulation from bearing casing Removing safety segments releasing casing u Take nuts 90458 out of toolbox and screw them onto threaded studs of safety segments 76080 on internal part of compressor cas ing 76000 u Tighten nuts 90458 to a maximum torque of 30 Nm The internal part of the compressor casin...

Page 90: ... later u Using press off screws 90900 push apart the compressor casing in ternal part 76000 until the lifting device 90190 90195 can be at tached u Slightly lift and then withdraw the compressor casing internal part in cluding the wall insert and diffuser u Attach the support angle 90025 using screws 90021 and nuts 74027 u Put down the compressor casing internal part including the wall in sert and...

Page 91: ...rn internal part of compressor casing complete with wall insert and diffuser about support angle 90025 and put onto under lay u Set down casing on flange F u Set down internal part of compressor casing in such a way that lifting device 90190 90195 can be removed WARNING Ensure that the shim does not slip u Rest the internal part of the compressor casing only on flange F u Check shim and adjust as ...

Page 92: ...erved HZTL2485_EN Revision E July 2017 Removing diffuser and wall insert u Remove screws 76002 u Remove diffuser 79000 using swivel lifting eyes 90235 u Press away wall insert 77000 using press off screws 90230 and re move from internal part of compressor casing 76000 using swivel lifting eyes 90235 Page 90 133 ...

Page 93: ...0195 to external part of compressor casing 74000 using screws and secure to crane u Remove screws 42280 u Uniformly press away external part of compressor casing 74000 us ing press off screws 90900 and remove NOTICE Insulation on external part of compressor casing The insulation on the external part of the compressor casing does not need to be taken off when removing or fitting the casing u Remove...

Page 94: ...fice 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 ensured that the orifice plates that are specified for the turbocharger have been installed in the two oil inlet channels u Check correct installation of oil orifice plates Version with com...

Page 95: ... rod 90490 onto threaded stud X to balance cartridge group u Evenly press off cartridge group by screwing press off screws 90900 into the designated holes CAUTION If the blades have insufficient or no clearance between the rotor and the casing the blades and the casing may be damaged u Check that the blades do not rub on the turbine diffuser by rotating the rotor u Withdraw cartridge group u Remov...

Page 96: ...ts reserved HZTL2485_EN Revision E July 2017 8 6 Dismantling and installing the turbine diffuser and nozzle ring Removing turbine diffuser u Put assembly plate 90020 over strain bolts 61036 u Insert extension A of torque spanner B through hole in assembly plate and loosen screws 61056 one after other u Don t remove screws 61056 yet Page 94 133 ...

Page 97: ...e 90020 over studs 61036 u Screw nuts 61037 onto start of threads of studs 61036 to secure u Remove remaining screws 61056 u Press away turbine diffuser 63000 using press off screws 90901 and withdraw it until assembly plate 90020 touches nuts 61037 u Loop lifting gear around turbine diffuser 63000 and secure to crane u Remove nuts 61037 and assembly plate 90020 from studs u Fully withdraw turbine...

Page 98: ...ll out nozzle ring 56001 u Remove threaded stud 56021 CAUTION Fastening the nozzle ring When fitting the nozzle ring new threaded studs 56021 nuts 56022 and locking plates 56018 from the customer spare part set 97070 must be used CAUTION Clogged areas on the nozzle ring If a nozzle ring is clogged in some areas or is covered by loose parts it is recommended to appoint an ABB Turbocharging Service ...

Page 99: ... new threaded studs 56021 nuts 56022 and locking plates 56018 from the customer spare part set 97070 must be used u Push in nozzle ring 56001 as far as it will go at the cover of the gas inlet casing u Coat threads of threaded studs 56021 with high temperature grease and fit threaded studs Fit the locking plates 56018 and nuts 56022 u Tighten nuts 56022 and bend locking plates 56018 over CAUTION C...

Page 100: ...rking TOP with position of gas outlet flange and pay atten tion to where positioning pin is in gas outlet casing u Fit turbine diffuser 63000 to guide studs 90320 u Put assembly plate 90020 over strain bolts 61036 and guide studs 90320 u Remove lifting gear and push in turbine diffuser u Using three screws 61056 alternately and uniformly screw in turbine diffuser as far as it will go u Insert torq...

Page 101: ...ve been installed in the two oil inlet channels u Check correct installation of oil orifice plates u Remove cover from oil connection u Fit flange 42044 with new gasket 42045 and screws 42064 u Check lifting gear and attach to bearing casing 42001 in such a way that cartridge group is suspended in a straight position u Screw guide rod 90490 onto threaded stud X to balance cartridge group u Remove ...

Page 102: ...it the remaining oiled nuts 61037 complete with new Verbus Ripp washers 61051 and tighten with pre tightening torque MV see chapter Table of tightening torques u Tighten all nuts 61037 in a star pattern with tightening angle DW see chapter Table of tightening torques u Remove the lifting gear u Remove guide rod 90490 u Screw in the speed sensor 86505 together with the O ring 86506 and plug in the ...

Page 103: ...L2485_EN Revision E July 2017 Fitting external part of compressor casing u Fasten lifting device 90190 90195 to external part 74000 of com pressor casing and secure it with crane u Fit O ring 42012 u Fit external part of compressor casing 74000 and fasten using screws 42280 u Remove lifting device 90190 90195 Page 101 133 ...

Page 104: ...les in wall insert 77000 u Align mark A with notch B u Fit centering screws 90230 in such a way that spigots on centering screws protrude maximum 5 mm u Lower wall insert and align centering screws 90230 with threaded holes u Remove swivel lifting eyes 90235 and centering screws 90230 u Put the diffuser 79000 in place using the swivel lifting eyes 90235 u Remove the swivel lifting eyes 90235 u Fit...

Page 105: ...sion E July 2017 Turning transporting internal part of compressor casing u Fasten lifting device 90190 90195 to front side of flange F u Carefully turn internal part of compressor casing 76000 complete with wall insert and diffuser about support angle 90025 and lift up vertically WARNING Ensure that the shim does not slip Page 103 133 ...

Page 106: ...90458 of the three safety segments have been tightened safety segments are in the not engaged position u Fit O ring 76040 u Remove the support angle 90025 screws 90021 and nuts 74027 u Align the compressor casing internal part 76000 with the com pressor casing external part as shown in the illustration on the next page u Carefully insert the compressor casing internal part 76000 including the wall...

Page 107: ...d HZTL2485_EN Revision E July 2017 NOTICE Align the compressor casing internal part 76000 with the notch see the arrow so that the notch is positioned at the rib of the compressor casing external part 74000 see the arrow u Fully insert the compressor casing internal part 76000 u Fit the studs 74026 74029 Page 105 133 ...

Page 108: ...essor casings 74000 76000 is not guaranteed u Fit four nuts 74027 complete with washers 74018 equally spaced around circumference and tighten u Unscrew nuts 90458 on threaded studs of safety segments 76080 on internal part of compressor casing 76000 The internal part of the compressor casing 76000 is now secure relat ive to the external part 74000 NOTICE Note the control dimension s The safety seg...

Page 109: ...ause injuries u Wear safety gloves Wear safety gloves to protect against mechanical hazards u Measure and note axial clearance A Clearance A mm TPL76 C 0 43 0 69 CAUTION If the axial clearance A is out of tolerance an official ABB Turbo Sys tems service station must be contacted u Connect oil lines and all air lines in accordance with engine builder specifications u Fit filter silencer or air suct...

Page 110: ...s recommended that you have a turbine blade inspection including a crack inspection carried out by an ABB Turbocharging Ser vice Station If provided w The fitted spiral wound gasket 61050 may be used only once u Make ready a new spiral wound gasket 61050 Disassembly u Remove insulation from gas inlet casing 51001 and disconnect clean ing pipe if provided u Secure gas inlet casing using lifting gea...

Page 111: ...85_EN Revision E July 2017 Segment connection u Undo screws 61044 and remove segments 51012 Flange connection u Undo and remove screws 61044 u Pull gas inlet casing 51001 complete with nozzle ring 56001 away from gas outlet casing 61001 CAUTION Use suitable underlays when putting down gas inlet casing 1 If present u Remove gasket 61050 Page 109 133 ...

Page 112: ...re part set 97070 must be used CAUTION Clogged areas on the nozzle ring If a nozzle ring is clogged in some areas or is covered by loose parts it is recommended to appoint an ABB Turbocharging Service Station to inspect the turbine blades and carry out a crack inspection Nozzle ring assembly u Carefully clean slots and contact surfaces of the casings and keep them free of metal chips u Keep slots ...

Page 113: ...d studs 56021 with high temperature grease and fit threaded studs Fit the locking plates 56018 and nuts 56022 u Tighten nuts 56022 and bend locking plates 56018 over CAUTION Correct assembly The nozzle ring must be easy to move after assembly 1 If present u Fix a new spiral wound gasket 61050 in the slot at three evenly dis tributed points with a little superglue for example Loctite 454 Gel u Posi...

Page 114: ... segment 51012 complete with roll pin on gas inlet casing fix it in correct radial position using centering bolt 90177 and then fit it loosely using screws 61044 NOTICE In only one of the three segments is there a roll pin as an aid when posi tioning the gas inlet casing This segment fits in only one position in the gas inlet casing note the circles in the illustration Consequently begin with this...

Page 115: ... must be marked on the component This enables simple and efficient tightening Tightening torques for screws 61044 Nm with spiral wound gasket Tightening TPL76 C Step 1 Screw in all screws hand tight Step 2 140 Step 3 280 Tightening torques for screws 61044 Nm without spiral wound gasket Tightening TPL76 C Step 1 Screw in all screws hand tight Step 3 280 Checking the tightening torque u Beginning w...

Page 116: ...N Revision E July 2017 Tightening flange connection u Fit screws 61044 u Tighten screws 61044 in accordance with following procedure and in following order Flange connection u Tighten screws crosswise NOTICE Screw tightening sequence The screw positioning numbers must be marked on the component This enables simple and efficient tightening Page 114 133 ...

Page 117: ...crew in all screws hand tight Step 2 140 Step 3 280 Tightening torques for screws 61044 Nm without spiral wound gasket Tightening TPL76 C Step 1 Screw in all screws hand tight Step 3 280 Checking the tightening torque u Beginning with screw 1 tighten all screws in a clockwise direction with tightening torque from step 3 u Remove lifting gear from gas inlet casing 51001 u Connect cleaning pipe if p...

Page 118: ...Operation Manual TPL76 C 8 Disassembly and assembly 8 9 Table of tightening torques Copyright 2017 All rights reserved HZTL2485_EN Revision E July 2017 8 9 Table of tightening torques Page 116 133 ...

Page 119: ... 86505 M18x1 5 150 Key to table 1 Place new Verbus Ripp washers onto strain bolts 7 New Verbus Ripp washers must be fitted every time the unit is assembled 2 a Tighten three nuts at 120 intervals to pre tightening torque MV lightly oil contact surface of nut b Tighten the remaining nuts with pre tightening torque MV c Tighten all nuts in a star pattern with tightening angle DW 3 After putting a ne...

Page 120: ...e situation stop the engine u Seal the oil leak u Soak up oil and dispose of in an environmentally compatible manner Wear safety gloves to protect against thermal hazards CAUTION Directives for taking out of operation Serious damage to engine or property can be caused by non compli ance with the directives for locking blanking off the turbocharger on the engine u Follow the directives of the engin...

Page 121: ...es 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 lubric ating 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 f...

Page 122: ...6 M8 25 Nm NOTICE Carry out work as described in the chapter Disassembly and assembly u Remove silencer or air suction branch u Insert lifting device 90427 into compressor wheel u Twist screws 94006 into free threaded holes in compressor wheel and tighten to values shown in Table of tightening torques CAUTION Don t remove any balancing screws from the compressor wheel Use only free threaded holes ...

Page 123: ... compressor wheel until holes in lifting device 90427 align with holes in assembly disassembly device 90020 u Fasten assembly disassembly device to lifting device 90427 using screws 94006 u Secure assembly disassembly device 90020 to compressor housing by screwing nuts 74027 onto studs 74026 See also chapter Table of tightening torques Fitted assembly plate CV 33 CV 34 CAUTION Make sure all compon...

Page 124: ...charger must be removed 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 wi...

Page 125: ... cover plate NOTICE The cover plate material General structural steel in accordance with DIN EN 10025 2 must be manufactured in house according to the drawing Cover plate dimensions mm Product B1 B2 B3 B4 B5 B6 B7 B8 TPL76 C 13 470 50 50 9 12 8 82 Product Ø 1 Ø 2 Ø 3 Ø 4 Ø 5 Ø 6 TPL76 C 915 990 950 20 28 20 Product 1 2 3 TPL76 C 4 x 90 37 5 24 x 15 Page 123 133 ...

Page 126: ...g out of operation at short notice 9 3 Fit cover plate Copyright 2017 All rights reserved HZTL2485_EN Revision E July 2017 NOTICE Carry out the work as described in the chapter Removal and fitting u Remove cartridge group Page 124 133 ...

Page 127: ... cover plate Copyright 2017 All rights reserved HZTL2485_EN Revision E July 2017 u Close off opening in gas outlet casing using cover plate u Fasten cover plate using spacer sleeves and nuts 61037 CAUTION Shut off the supply of lubricating oil to the turbocharger Page 125 133 ...

Page 128: ...tions 4 stroke engine with several turbochargers Separate receivers 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 Common receiver The air line must be closed off at the engine end because the undam aged turbochargers build up a receiver pressure CAUT...

Page 129: ... off compressor casing outlet gas inlet and gas outlet by fitting cover plates NOTICE In this respect refer to the engine manufacturer s instructions 9 5 Bypass the turbocharger CAUTION Shut off the lubricating oil supply to the turbocharger w This applies to engines with one turbocharger only w The connections are ready and pipes for the bypass are available u Fit bypass around turbocharger NOTIC...

Page 130: ...nd this is circulated by the prelubrica tion pump no measures have to be taken Any remaining old engine oil will thus be flushed away and the bearing sections largely protec ted 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 u Remove turbocharger u Rotor and bea...

Page 131: ...n for up to 12 months under Mothballing measures for the measures always necessary when moth balling 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 as sembled next to the engine using the individual parts...

Page 132: ...tory mask to protect against dusts Wear safety gloves to protect against mechanical hazards 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 materials filter components of felt and pol...

Page 133: ...parts All spare parts ordered with the turbocharger must be kept complete and ready for use u Parts showing signs of rust should be carefully cleaned and greased u Dispose of replaced and unusable parts in a professional and environ mentally compatible way Required customer spare part set 97070 The customer spare part set 97070 is required for the work described in this Operation Manual These part...

Page 134: ...ration Manual TPL76 C 12 Spare parts 12 2 View of turbocharger with part numbers Copyright 2017 All rights reserved HZTL2485_EN Revision E July 2017 12 2 View of turbocharger with part numbers Page 132 133 ...

Page 135: ...044 in customer spare part set Hexagon head screw 61050 in customer spare part set Gasket 61051 in customer spare part set Verbus Ripp washer 61056 in customer spare part set Hexagon head screw 61065 Gasket 61066 Blind flange 61067 Hexagon head screw 63000 Turbine diffuser 68001 Foot at compressor end 68002 Foot at turbine end 68006 Cup spring 68007 Bush 61079 Gasket 74000 Compressor casing extern...

Page 136: ...ABB Turbo Systems AG Bruggerstrasse 71a CH 5400 Baden Switzerland ABB ...

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