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Operation Manual / TPL67-C.. - TPL71-C..

Table of contents

HZTL2488_EN

Revision E

August 2018

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

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

1.5

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

1.6

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

1.7

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

1.8

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 .................................................................................................... 45

Maintenance .......................................................................................................... 46

5.1

Foreword to Maintenance .......................................................................................... 46

5.2

Cleaning the filter silencer........................................................................................... 47

5.3

Cleaning the compressor during operation ........................................................... 50

5.4

Cleaning turbine blades and nozzle ring in operation ........................................... 56

5.5

Cleaning components mechanically.......................................................................... 61

Summary of Contents for HT582771

Page 1: ... Systems Ltd CH 5401 Baden Type TPL71 C35 HT582771 nMmax 410 t Mmax 650 nBmax 397 t Bmax 620 1 s C 02040 35 50 50 Year 2018 made in Switzerland Application according to the Operation Manual kg HZTL2488 English TPL71 C35 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: ...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 Replacement ...

Page 4: ...e 87 8 5 Removing cartridge group 87 8 6 Dismantling and installing the turbine diffuser and nozzle ring 92 8 7 Installing cartridge group 95 8 8 Dismantling and fitting nozzle ring at turbine end 100 8 9 Table of tightening torques 104 9 Taking out of operation at short notice 106 9 1 Possibilities for emergency repair 106 9 2 Locking the rotor 107 9 3 Fit cover plate 111 9 4 Blocking the inlets ...

Page 5: ...Systems 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 engi...

Page 6: ...d HZTL2488_EN Revision E August 2018 1 2 Layout and function TPL67 71 C 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 4 125 ...

Page 7: ...then passes through the diffuser 11 and leaves the turbocharger through the com pressor casing 13 The rotor runs in two radial plain bearings 02 05 One plain bearing is in the bearing bush 04 and the second one is in the axial thrust bearing 03 at the compressor end The plain bearings are connected to a central lubricating oil duct which is fed with oil from the engine s lubricating oil circuit Th...

Page 8: ...d The specific operating limits of the turbocharger were 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 ...

Page 9: ... is designed and built according to the state of the art and is safe to operate Flawless condition The turbocharger must only be used when it is in a technically flawless condition and operated in compliance with its intended use ABB Turbo Systems excludes any liability for damage resulting from un authorized modifications to the turbocharger or improper operation Page 7 125 ...

Page 10: ...roducts 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 pro...

Page 11: ...ng Service 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 ...

Page 12: ...and wearing of personal protective equipment NOTICE The manner in which personnel work on and with the turbocharger with regard to safety and risks is to be checked on a regular basis in accord ance with the Operation Manual u The turbocharger must be shut down immediately in the event of modifications affecting safety or of corresponding operating beha viour by stopping the engine The fault shoul...

Page 13: ...ence of personnel The turbocharger must only be operated and serviced by trained and au thorised personnel Basic mechanical training is a prerequisite Design variants This document is valid for different design variants of turbochargers There may be sections and descriptions of components that are not rel evant for a specific turbocharger variant ABB Turbocharging Service Stations will be happy to...

Page 14: ...uct Definition of mandatory signs Mandatory signs show the protective equipment to be worn for a task The mandatory signs are described in chapter Safety and must be 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 Ser...

Page 15: ... agreed 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 ...

Page 16: ...at overload 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 7 2 Positions of the rating plates A rating plate is attached to the turbocharger foot one on the left ...

Page 17: ...nce of 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 ...

Page 18: ...ar protection 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 si...

Page 19: ...g plates 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 17 125 ...

Page 20: ...he turbocharger 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 bi...

Page 21: ...mage 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 ar...

Page 22: ...t the 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 ...

Page 23: ...bocharger 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 ha...

Page 24: ...e 85 dB A always wear ear protection Wear ear protection Hazards due to hot surfaces and substances During operation turbocharger surfaces and attached parts as well as 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 WAR...

Page 25: ...harger 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 easi...

Page 26: ...ntamination 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 adequate...

Page 27: ...area u Take particular care when removing old insulating materials u Dispose of insulating materials properly and in an environmentally compatible way in accordance with applicable local regulations Wear safety goggles Wear a respiratory mask to protect against dusts Wear safety gloves to protect against chemical hazards u Use only suitable non combustible insulating materials u Ensure that the wo...

Page 28: ...els must be observed The operating company is responsible for the safe operation of the pressure vessel WARNING Danger due to pressure vessels The operating 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 no...

Page 29: ...e loading 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 rem...

Page 30: ... 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 Filtration of the lubricating oil using a filter mesh size 0 034 mm is ad equate for TPL67 C turbochargers and a mesh size...

Page 31: ...urbocharger 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 lubrication engine stopped 0 2 2 5 Oil orifice A metering orifice is installed in the oil inlet of the turboc...

Page 32: ...oil temperature at the outlet The oil temperature at the outlet is mainly dependant on Lubricating oil temperature and pressure at the oil inlet Engine load and turbocharger speed Exhaust gas temperature The maximum admissible oil temperature at the outlet is listed in the fol lowing table The specified oil outlet temperature is to be considered as alarm value for the turbocharger operation and mu...

Page 33: ...ontaminated 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 supp...

Page 34: ...s temperature 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 afte...

Page 35: ...uct before 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 ti...

Page 36: ...rbocharger 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...

Page 37: ...yright 2018 All rights reserved HZTL2488_EN Revision E August 2018 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 35 125 ...

Page 38: ...ortened 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 ...

Page 39: ...acturer 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 ...

Page 40: ... air 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 and the inspection and assessment of the rotor must be carried out by an ABB Turbocharging Service Station u Disassemble turbocharger u Clearance measurement u Clean the turbine and compressor wheels and...

Page 41: ...ent intervals 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...

Page 42: ...S MDO 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 Se...

Page 43: ...ing system 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 41 125 ...

Page 44: ...ing steps must be carried out u Reduce engine performance immediately until the highest turbochar ger speed no longer exceeds 70 of nBmax u If the engine cannot be stopped continue to run at this reduced en gine performance or turbocharger speed u If the turbocharger surges continuously engine performance must be reduced further u Measure the temperatures in the air and gas lines to and from the t...

Page 45: ...it it w Engine and turbocharger are not running w The turbocharger lubricating system is switched off u Remove screw plug 42047 from bearing casing NOTICE Part position The position of the screw plug for measuring the speed is marked n on the bearing casing u Screw in speed sensor 86505 as far as it will go and tighten to torque specified in table See chapter Table of tightening torques u Connect ...

Page 46: ...stop the engine u Switch off the lubricating oil supply to the turbocharger u Disconnect the cable connector from the speed sensor u Screw out defective speed sensor u Screw in a new speed sensor to the stop 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 seal...

Page 47: ...ts reserved HZTL2488_EN Revision E August 2018 4 5 Stopping the engine CAUTION Stopping the engine Heat in the turbocharger must be dissipated by the further circulating lubricating oil u Allow the engine to continue running at idling speed for a further 10 minutes before stopping Page 45 125 ...

Page 48: ...hecks 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 Co...

Page 49: ...n E August 2018 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 47 125 ...

Page 50: ...r is Clean filter strip every 500 hours of service or more frequently if necessary u Unscrew and remove lock nuts 81273 u Unscrew and remove screws 81272 for connecting rods 81269 u Remove connecting rods 81269 u Carefully remove cover grids 81266 u Pull out insert units E bend open sheet metal coverings 81137 and then remove absorption segments 81136 u Clean the absorption segments 81136 During c...

Page 51: ...gh the lugs of cover grids 81266 CAUTION If connecting rods 81269 are not correctly positioned in their recesses on filter silencer body 81135 cover grid 81266 can twist and shift There is then a risk of foreign matter and contamination getting into the compressor u Join connecting rods 81269 using screws 81272 When tightening the screws 81272 ensure that connecting rods 81269 are located correctl...

Page 52: ... channels 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 tu...

Page 53: ... of contamination is not too high CAUTION Corrosion and deposits when cleaning Damage and impairment of turbocharger parts due to salt water and cooling water 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 specif...

Page 54: ...nt 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 add...

Page 55: ...ary If 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 ...

Page 56: ...s been tested and is recommended by ABB Turbo Systems the following pre requisites must be fulfilled ü Engine load 50 85 u Start of cleaning cycle in accordance with following description for 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 fulfi...

Page 57: ...oad Water temperat ure C Contents of wa ter vessel dm3 TPL67 C 71 C 50 85 5 50 0 4 or 1 Surging 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 despit...

Page 58: ... drop 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 essen...

Page 59: ...s been 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 58 CAUTION Reduced service life of the components Failure to comply with the minimum stabilisation time before cleaning the prescribed turbine inlet t...

Page 60: ...g operating 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 ...

Page 61: ...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 u Close drain hole if provided above drain pipe 08 09 u After cleaning wait with engine running for at...

Page 62: ...ual 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 cleaning typic...

Page 63: ...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 u In the event of heavy contamination the cleaning methods de scribed in this chapter such as soaking can be repeated until...

Page 64: ...ggles 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 u Place contaminated parts in hot water or in a liq...

Page 65: ...ain 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 the cart ridge group u Make sure that no water or contamination can enter into the cart ridge ...

Page 66: ...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 gear must not touch the compressor...

Page 67: ...HZTL2488_EN Revision E August 2018 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 65 125 ...

Page 68: ...gear 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 outl...

Page 69: ...k until 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 N...

Page 70: ...unction 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 V...

Page 71: ...r unbalance 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 co...

Page 72: ... Rotor 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 m...

Page 73: ... surging 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 cond...

Page 74: ... ger Rotor axial clearance too large Contact an ABB Turbocharging Service Station Reduction in speed Possible causes Elimination Engine Defects of connected cylinders when pulse charging Contact the enginebuilder Turbochar ger Heavy contamination of the turbine Clean it Damaged rotor components or bearing Contact an ABB Turbocharging Service Station Pipes Defects such as leaks in the ex haust gas ...

Page 75: ...vation 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 Enlarged flow cross section of the nozzle ring due to de formed blade trailing edges Contact an ABB Turbocharging Service Station Damaged or eroded turbine Charge air cooler Cooler contaminated Clean it Cooling water volume ...

Page 76: ... manometer 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 ...

Page 77: ...wn Possible causes Elimination Turbochar ger Turbocharger contaminated Clean it Damaged bearing Contact an ABB Turbocharging Service Station Rubbing rotor Foreign object in turbocharger Run down time too short Possible causes Elimination Turbochar ger Turbocharger contaminated Clean it Damaged bearing Contact an ABB Turbocharging Service Station Rubbing rotor Foreign object in turbocharger Page 75...

Page 78: ... lems 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 tri...

Page 79: ...moval and installation 7 1 Turbocharger weights 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 Weights kg TPL67 C TPL71 C 1330 2040 Page 77 125 ...

Page 80: ...es that are specified for the turbocharger have been installed in the two oil inlet channels u Check correct installation of oil orifice plates Use the two suspension eyes on the bearing casing observe the mark ing on the insulation The lifting gear around the gas inlet casing serves to align the turbocharger horizontally u Remove the insulation shell S from the bearing casing and possibly the ins...

Page 81: ...aring casing u Loosen the fixing screws at the foot u 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 u Wear personal protective equipment PPE u Support the turbocharger at a suitable poin...

Page 82: ... 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 u Fit the turbocharger to the engine u Tighten the fixing screws at the foot in accordance with the engine builder s instructions u Fasten the gas...

Page 83: ...e 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 assembly devices but replace them Customer spare parts set Before beginning work ensure that the required customer spare parts sets are available u See chapter Spare part...

Page 84: ...operly 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 component or an assembly blind hole thread eye lug Assembly device Devices that are fitted on the turbocharger in order to obtain a sus pension point Assembly devices are speci...

Page 85: ...rts or assemblies are guides roun ded off to the next highest value Assemblies Weights kg Description TPL67 C TPL71 C 1 Filter silencer 130 180 2 Radial air suction branch 50 70 3 Compressor casing 180 260 4 Wall insert 40 65 5 Diffuser 19 35 6 Cartridge group 290 460 7 Turbine diffuser 40 60 8 Nozzle ring 10 13 9 Radial gas inlet casing 110 150 10 Segment 7 12 11 Axial gas inlet casing 65 80 Page...

Page 86: ...right 2018 All rights reserved HZTL2488_EN Revision E August 2018 Complete compressor casing Weight kg TPL67 C TPL71 C 240 360 NOTICE The total weight of the complete compressor casing is an addition of the weights of the compressor casing the diffuser and the wall insert Page 84 125 ...

Page 87: ...ct all air lines in accordance with the engine builder s instruc tions u Dismantle the insulation where necessary u Pass a lifting gear around the air suction branch It is permissible to pass the lifting gear through holes possibly provided in the ribs to im prove stability u Unscrew the nuts 72027 and remove them together with the wash ers 72018 u Remove the air suction branch and set it down to ...

Page 88: ...sion E August 2018 Removing filter silencer u Remove insulation where necessary u Pass lifting gear through rib on filter silencer u Pass lifting gear through lugs on back u Unscrew nuts 72027 and remove them together with washers 72018 u Remove filter silencer and it set down to one side Installing the filter silen cer u Install filter silencer in reverse order Page 86 125 ...

Page 89: ... to protect against mechanical hazards The axial clearance A must be measured before removing and after fit ting the cartridge group u Measure and note the axial clearance A Clearance A mm TPL67 C TPL71 C 0 31 0 49 0 33 0 50 CAUTION Clearances outside the tolerance Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts u Have the componen...

Page 90: ...ty u Disconnect oil pipes in accordance with enginebuilder s instructions CAUTION Oil orifice plates An orifice plate for adjusting the oil pressure is fitted in each of the two oil inlet channels in the bearing casing When the cartridge group the bearing casing or the turbocharger is fitted to the engine it must be ensured that the orifice plates that are specified for the turbocharger have been ...

Page 91: ... three studs 72029 at top u Attach lifting device 90190 to compressor casing 72000 then fasten and secure it to crane using lifting gear u Unscrew and remove nuts 61037 u Uniformly press off compressor casing 72000 using three press off nuts 61090 fitted on bearing casing side u Slightly lift and pull out compressor casing 72000 u Remove the O ring 42012 Page 89 125 ...

Page 92: ...h wall insert and dif fuser and put them down with surface F on underlay WARNING Make sure that the underlay does not slip u Allow compressor casing to rest only on surface F u Check underlay and adjust if necessary u Remove screws 72002 u Remove diffuser 79000 using swivel lifting eyes 90235 u Remove wall insert 77000 using swivel lifting eyes 90235 u Remove O ring 77005 from wall insert Page 90 ...

Page 93: ...m together with the Verbus Ripp washers 61058 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 Check that the blades do not rub on the turbine diffuser by rotating the rotor u Withdraw cartridge group u Fit supports 90450 u...

Page 94: ... E August 2018 8 6 Dismantling and installing the turbine diffuser and nozzle ring Releasing the turbine dif fuser u Put clamp 90921 over stud 61036 until it rests on inner radius of gas outlet casing u Pass extension A of torque spanner B through hole in clamp and only loosen screws 61056 one after other u Do not yet remove the screws 61056 and Verbus Ripp washers 61057 Page 92 125 ...

Page 95: ...it clamps 90921 over guide studs 90320 and studs 61036 u To secure the work screw nuts 61037 onto start of stud threads 61036 u Remove the remaining screws 61056 and Verbus Ripp washers 61057 u Press the turbine diffuser 63000 free using the press off screws 90901 and pull it out it until the clamp 90921 is touching the nut 61037 u Loop the lifting gear around the turbine diffuser 63000 and secure...

Page 96: ...r has been removed the nozzle ring 56001 is only clamped lightly with the gas outlet casing By pulling forward the nozzle ring 56001 is released and can drop down u Pull nozzle ring 56001 forward and remove Installing the turbine diffuser and nozzle ring u Install the nozzle ring and turbine diffuser in the reverse order of re moval u Coat the screw threads with high temperature grease u Align noz...

Page 97: ...ce plates An orifice plate for adjusting the oil pressure is fitted in each of the two oil inlet channels in the bearing casing When the cartridge group the bearing casing or the turbocharger is fitted to the engine it must be 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 ...

Page 98: ... the bearing casing provided for this purpose u Remove supports 90450 and carefully insert cartridge group CAUTION If the rotor blades have insufficient or no clearance the blades and cas ing could be damaged u Check that the blades do not rub on the turbine diffuser by rotating the rotor u Uniformly tighten the three screws 61059 with Verbus Ripp wash ers 61058 u Remove the lifting gear u Screw i...

Page 99: ...vision E August 2018 u Fit the O ring 77005 to the wall insert 77000 u Fit the swivel lifting eyes 90235 and attach lifting gear u Align the wall insert 77000 using the centering screw 90187 and fit it u Put the diffuser 79000 in place using the swivel lifting eyes 90235 u Remove the swivel lifting eyes 90235 u Fit screws 72002 Page 97 125 ...

Page 100: ...he compressor casing 72000 u Screw three press off nuts 61090 onto bearing casing studs equally distributed around circumference and screw up to end of thread by hand u Push the compressor casing 72000 flush onto the cartridge group and attach with nuts 61037 u Secure the three press off nuts 61090 against the compressor cas ing 72000 with the appropriate tightening torque see chapter Table of tig...

Page 101: ... clearance CAUTION If the axial clearance A is out of tolerance an ABB Turbocharger ser vice station must be contacted u Connect oil pipes and all air lines in accordance with enginebuilder specifications Version with compressor wheel cooling system u Fit the air supply line See also chapter entitled Preliminary remarks Layout and functionality u Fit the filter silencer or air suction branch u Fit...

Page 102: ...1050 may only be used once u Provide a new spiral wound gasket 61050 Disassembly u Remove the insulation from the gas inlet casing 51001 and discon nect the cleaning pipe if provided u Secure the gas inlet casing using a lifting gear CAUTION When looping the rope around the casing make sure that no cleaning pipes are crushed or damaged Do not under any circumstances fasten the lifting gear to the ...

Page 103: ...ge connection u Remove two screws 61044 in lower section u Fit two guide studs 90320 as a safety measure u Remove remaining screws 61044 u Pull gas inlet casing complete with nozzle ring away from gas outlet casing until nozzle ring can be lifted away u Remove gas inlet casing and put it down CAUTION Use suitable underlays when putting down gas inlet casing 1 If present u Remove spiral wound gaske...

Page 104: ...ve for example Loctite 454 gel applied at three equally spaced points in groove u Fit nozzle ring to gas inlet casing and fix it u Fit gas inlet casing u Use guide studs 90320 as a centering aid and remove them after wards u Brush screw threads 61044 with high temperature grease Segment connection u Position segments 51012 using screws 61044 Checking Make sure that collars C of segments 51012 rest...

Page 105: ...The screw positioning numbers must be marked on the component This enables simple and efficient tightening Tightening torques for screws 61044 Nm with spiral wound gasket Tightening TPL67 C TPL71 C Step 1 Screw in all screws by hand Step 2 40 60 Step 3 80 130 Tightening torques for screws 61044 Nm without spiral wound gasket Tightening TPL67 C TPL71 C Step 1 Screw in all screws by hand Step 3 80 1...

Page 106: ...eration Manual TPL67 C TPL71 C 8 Disassembly and assembly 8 9 Table of tightening torques Copyright 2018 All rights reserved HZTL2488_EN Revision E August 2018 8 9 Table of tightening torques Page 104 125 ...

Page 107: ...g torques Nm Part number TPL67 C TPL71 C 1 82005 M16x1 5 45 M16x1 5 45 3 72002 M10 50 M12 80 4 72027 with washer M14 95 M16 125 5 72029 with washer M14 30 M16 30 6 61037 M16 110 M18 160 6a 61090 M16 10 M18 15 7 61036 M16 30 M18 40 8 61059 M16 200 M18 280 9 42059 M12 80 M16 180 17 61044 M12 80 M14 130 21 61056 M12 105 M14 130 29 86505 M18x1 5 150 M18x1 5 150 Page 105 125 ...

Page 108: ...on the 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 ...

Page 109: ...metimes 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 informat...

Page 110: ... the chapter Disassembly and As sembly u Insert locking flange 94003 into compressor wheel u Put screws 94007 into unoccupied threaded holes in compressor wheel and tighten to values shown in Table of tightening torques CAUTION Do not remove any balancing screws from compressor wheel Use only unoccupied threaded holes to fit lifting spigot u Position assembly disassembly device 90020 over studs 72...

Page 111: ...served HZTL2488_EN Revision E August 2018 u Secure assembly disassembly device 90020 to compressor casing by screwing nuts 72027 complete with washers 72018 onto studs 72026 and then tightening to values shown in preceding Table of tightening torques CAUTION Make sure all components are clean and free from grease Page 109 125 ...

Page 112: ...turbocharger 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 casi...

Page 113: ...l 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 TPL67 C 13 325 30 30 8 10 6 70 TPL71 C 13 385 30 30 8 10 6 84 Product Ø 1 Ø 2 Ø 3 Ø 4 Ø 5 min Ø 6 min TPL67 C 616 694 660 16 22 15 TPL71 C 726 818 779 18 25 15 Product 1 2 3 TPL67 C 4 x 90 37 5 24 x 15 TPL71 C 4 x 90 37 5 24 x...

Page 114: ...ut of operation at short notice 9 3 Fit cover plate Copyright 2018 All rights reserved HZTL2488_EN Revision E August 2018 NOTICE Carry out the work as described in the chapter Disassembly and As sembly u Removing the cartridge group Page 112 125 ...

Page 115: ...3 Fit cover plate Copyright 2018 All rights reserved HZTL2488_EN Revision E August 2018 u Close 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 113 125 ...

Page 116: ...structions 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...

Page 117: ... Shut off compressor casing outlet gas inlet and gas outlet by fitting cover plates NOTICE In this respect refer to the engine manufacturer s instructions 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 ...

Page 118: ...and 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 be...

Page 119: ...tion 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 pa...

Page 120: ...spiratory 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 an...

Page 121: ...of spare 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 T...

Page 122: ...tem should be carried out only by an ABB Turbocharging service station Axial gas inlet casing Quantity Description Part number 6 Locking plate 51255 3 Gasket 52200 2 Hexagon head screw 52204 2 Hexagon head screw 52205 3 Nozzle 52208 2 Hexagon head screw 52257 Radial gas inlet casing Quantity Description Part number 4 Locking plate 51255 3 Gasket 52200 2 Hexagon head screw 52204 2 Hexagon head scre...

Page 124: ...n Manual TPL67 C TPL71 C 12 Spare parts 12 2 View of turbocharger with part numbers Copyright 2018 All rights reserved HZTL2488_EN Revision E August 2018 12 2 View of turbocharger with part numbers Page 122 125 ...

Page 125: ...ut 61044 Hexagon head screw 61050 if provided Gasket 61056 in customer spare part set Hexagon head screw 61057 in customer spare part set Verbus Ripp Washer 61058 in customer spare part set Verbus Ripp Washer 61059 in customer spare part set Hexagon head screw 63000 Turbine diffuser 68001 Foot at compressor end 68002 Foot at turbine end 68003 Slide plate 68006 Cup spring 68007 Bush 72000 Compresso...

Page 126: ...View of turbine cleaning system with part numbers optional Axial gas inlet casing Part number Description 51229 Cleaning pipe 52249 Holder complete 51255 in spare parts set Locking plate 52200 in spare part set Gasket 52204 in spare part set Hexagon head screw 52205 in spare part set Hexagon head screw 52208 in spare part set Nozzle 52257 in spare part set Hexagon head screw Page 124 125 ...

Page 127: ...ipe 52249 Holder complete 51255 in spare parts set Locking plate 52200 in spare part set Gasket 52204 in spare part set Hexagon head screw 52205 in spare part set Hexagon head screw 52208 in spare part set Nozzle 52209 in spare part set Nozzle 52210 in spare part set Nozzle 52213 in spare part set Locking plate 52219 in spare part set Hollow screw 52257 in spare part set Hexagon head screw 52258 i...

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

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