ABB HT584444 Operation Manual Download Page 5

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Operation Manual / TPL65VA32/33

Table of contents

Page 3

ber

2016

L2464_

ion

Mothballing the turbocharger

10.1

Taking the engine out of operation for up to 12 months

10.2

Taking the engine out of operation for more than 12 months

Disposing of turbocharger components

View of turbocharger with part numbers

Summary of Contents for HT584444

Page 1: ... Systems Ltd CH 5401 Baden Type TPL65VA33 HT584444 nMmax 499 t Mmax 650 nBmax 487 t Bmax 620 1 s C 01210 35 50 50 Year 2018 made in Switzerland Application according to the Operation Manual kg HZTL2464 English TPL65VA33 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: ...Contact information 2 Safety 2 1 Introduction 2 2 CE conformity 2 3 Definition of mandatory signs 2 4 Definition of Safety instructions 2 5 Warning plates on the turbocharger 2 6 Safe operation and maintenance 2 7 Hazards during operation and maintenance 2 8 Periodic checking of the pressure vessel 2 9 Lifting loads 3 Commissioning 3 1 Oil supply 3 2 Inspection work 3 3 Commissioning after taking ...

Page 4: ...riable Turbine Geometry 7 Removal and installation 7 1 Turbocharger weights 7 2 Removing the turbocharger 7 3 Installing the turbocharger 8 Disassembly and assembly 8 1 Introduction 8 2 Module weights 8 3 Removing and fitting filter silencer or air suction branch 8 4 Axial clearance 8 5 Removing cartridge group 8 6 Removing and fitting turbine diffuser 8 7 Removing variable turbine geometry module...

Page 5: ...16 HZTL2464_EN Revision D 10 Mothballing the turbocharger 10 1 Taking the engine out of operation for up to 12 months 10 2 Taking the engine out of operation for more than 12 months 11 Disposing of turbocharger components 12 Spare parts 12 1 Ordering spare parts 12 2 View of turbocharger with part numbers ...

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

Page 8: ...served December 2016 HZTL2464_EN Revision D Layout and function 1 2 01 Filter silencer 08 Nozzle ring 02 Radial plain bearing 09 Turbine wheel 03 Thrust bearing 10 Bearing casing 04 Bearing bush 11 Diffuser 05 Radial plain bearing 12 Compressor wheel 06 Gas outlet casing 13 Air outlet casing 07 Gas inlet casing 1 2 ...

Page 9: ...l 12 It then passes through the diffuser 11 and leaves the turbocharger through the air outlet 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 cir...

Page 10: ...y remarks 1 Layout and function 1 2 Page 8 Copyright 2016 ABB All rights reserved December 2016 HZTL2464_EN Revision D Additional function TPL V These turbocharger types have adjustable guide vanes at the turbine end instead of a nozzle ring ...

Page 11: ...facturer accepts no liability for other applications If it is used otherwise ABB Turbo Sys tems reserves the right to reject all warranty claims This turbocharger was built according to state of the art technology and is operationally safe according to recognised safety regulations WARNING Improper operation and maintenance of the turbocharger can result in danger to life and limb of the user or t...

Page 12: ... when handling VCIs VCI products are not hazardous in the sense of the Hazardous Sub stances Ordinance Nevertheless the following points are to be ob served when handling VCIs Ensure good room ventilation Do not eat drink or keep food at the workplace while working with VCIs Wear safety gloves Clean hands and face after working with VCIs For further information refer to www branopac com Wear safet...

Page 13: ...Turbocharging Service Station and repacked Inspect the package for damage If the package is damaged the tur bocharger or cartridge group must be inspected by an ABB Turbo charging Service Station and repacked After every 3 years the following work steps must be performed by an ABB Turbocharging Service Station Inspect the components Exchange the desiccant agent Repackage the components NOTICE Repl...

Page 14: ...lso applies to the provision and wearing of personnel protection equipment NOTICE The safety and risk consciousness of the personnel working on and with the turbocharger must be checked regularly with reference to this manual The turbocharger must be shut down immediately by stopping the en gine in the event of alterations affecting safety or of corresponding op erating behaviour The fault must be...

Page 15: ...riginal parts Operation of the turbocharger with non original parts can impair the safety of the turbocharger and can cause serious damage to property and injury to personnel Only use original parts from ABB Turbo Systems ABB Turbo Systems accepts no liability for any damage resulting from the use of non original parts and corresponding accessories Competence of personnel The turbocharger must onl...

Page 16: ...are not rele vant for a specific turbocharger variant ABB Turbocharging Service Stations will be happy to provide information on questions regarding a design variant see Contact information at www abb com turbocharging Accuracy of illustrations The illustrations in this document are general in nature and intended for ease of understanding Differences in detail are therefore possible Registered tra...

Page 17: ...e product Definition of mandatory signs Mandatory signs show the protective equipment to be worn for a task The mandatory signs are described in chapter Safety and must be complied with Definition of caution warning The caution and warning signs are described in the chapter Safety ABB Turbo Systems In this document ABB Turbo Systems Ltd is abbreviated to ABB Turbo Systems Official ABB Turbo System...

Page 18: ...th the en ginebuilder 02 Turbocharger operating limits during operation 03 Replacement interval for plain bearings in 1000 h 04 Replacement interval for compressor in 1000 h 05 Replacement interval for turbine in 1000 h 06 Customer part number 07 Designation of the special design 08 Turbocharger weight in kg 09 Turbocharger type 10 Serial number 11 Year of construction of turbocharger 12 Manufactu...

Page 19: ...hat you contact the nearest official ABB Turbocharging service station nMmaxand tMmax normally apply only when running at overload 110 during tri als on the engine test bed These limits can also be permitted during operation for special applications Operation above nMmax and tMmax is not permitted Non observance of the recommended replacement intervals can increase the risk of unpredictable compon...

Page 20: ...served December 2016 HZTL2464_EN Revision D Contact information 1 8 Contact information Contact information for the official service stations of ABB Turbo Systems is available online Scan the QR code to access our website ABB Turbo Systems Ltd Bruggerstrasse 71a CH 5401 Baden Switzerland www abb com turbocharging 1 8 ...

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

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

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

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

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

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

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

Page 28: ... dependent on the effectiveness of the insulation being used The tem perature can become high enough so that it falls into ranges where burns are possible WARNING Risk of burning Touching hot surfaces or contact with hot operating materials can lead to serious burns Do not touch hot surfaces and heed the warning plate on the turbo charger Wear heat resistant safety gloves and protective clothing A...

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

Page 30: ...and contact with the skin Ensure that the work space is adequately ventilated Seal containers tightly immediately after use and put them away Collect used working and auxiliary materials safely store them sepa rately in suitable containers and dispose of them properly and in an environmentally compatible manner in accordance with statutory regu lations In the event of leaks or after spilling immed...

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

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

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

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Page 35: ...onditions is an important prerequisite for trouble free tur bocharger operation The turbocharger is normally lubricated with oil from the engine oil circuit NOTICE With regard to the oil supply please observe the engine builder s speci fications for lubricating oil selection oil change intervals oil filtration oil pressure and oil temperature Oil filtration A lubricating oil filter system with a f...

Page 36: ...on the turbocharger 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 NOTICE Oil orifice A metering orifice is installed in the oil inle...

Page 37: ...oil 30 Lubricating 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 turbocharg...

Page 38: ...oughly with warm oil using a bypass pipe before starting up the first time commissioning and after all service work on the lubricating sys tem It is urgently recommended that a running in filter is used when running in the engine and after all service work on the lubricating system Check the oil pressure in the oil supply lines Check that variable turbine geometry module can be adjusted TPL65 Vers...

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

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

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

Page 42: ...40 Copyright 2016 ABB All rights reserved December 2016 HZTL2464_EN Revision D Suggestion for noise insulation of the bellows 01 Compressor casing 04 Insulation pads 02 Bellows 05 Insulation mat at least 15 mm 03 Charge air duct scavenging air line 06 Sheet metal cover ...

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

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

Page 45: ...rrosion Clean bearing casing and blow air through oil ports Inspect and assess sealing air lines Inspect and assess rotor and bearing parts Have the variable turbine geometry module overhauled by ABB Turbo Systems ABB Turbocharging Service Stations have variable turbine geometry modules replaced with overhauled ones as part of the CPEX Customer Part Exchange programme Service work every 30000 hour...

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

Page 47: ...ng 50000 100000 Variable turbine geometry module The variable turbine geometry module can be re placed with a CPEX variable turbine geometry module by an ABB Turbocharging service station 15000 Turbine diffuser cover ring 35000 50000 Other casings 100000 Axial bearing components 24000 36000 Radial bearing components 24000 36000 Turbine blades due to wear Rotor components See the data on the rating...

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

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

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

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

Page 52: ...ergency operation TPL VA 4 5 In the event of failure of the control system or the drive the variable tur bine geometry module can be fixed by clamping the ring lever B using at least 3 washers C spaced around the circumference When fixing the position of the variable turbine geometry module and or the blades must be specified by the enginebuilder 4 5 Detail A ...

Page 53: ... All rights reserved December 2016 HZTL2464_EN Revision D Stopping the engine 4 6 CAUTION Stopping the engine Heat in the turbocharger must be dissipated by the further circulating lubricating oil Allow the engine to continue running at idling speed for a further 10 minutes before stopping 4 6 ...

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Page 55: ...visual checks and clean ing to ensure that the turbocharger and its attached units function trouble free The external condition and how dirty the cleaning points specified in this chapter are must be established by visual checks at the specified intervals The safety precautions must be observed during all maintenance and servicing work The cleaning points described in the following are Filter sile...

Page 56: ...6 HZTL2464_EN Revision D Cleaning the filter silencer 5 2 Filter silencer and connecting rod 81265 Filter ring if provided 81136 Absorption segment 81269 Connecting rods 81137 Sheet metal covering 81266 Cover grid 81135 Filter silencer body 81272 Screwdriver 81273 Lock nut E Insert unit absorption segment sheet metal covering 5 2 5 2 1 ...

Page 57: ...n air is Clean filter strip every 500 hours of service or more frequently if necessary Unscrew and remove lock nuts 81273 Unscrew and remove screws 81272 for connecting rods 81269 Remove connecting rods 81269 Carefully remove cover grids 81266 Pull out insert units E bend open sheet metal coverings 81137 and then remove absorption segments 81136 Clean the absorption segments 81136 During cleaning ...

Page 58: ...1137 Bend sheet metal coverings 81137 back to original shape Insert the insert units E into slot guides in filter silencer unit 81135 Uniformly place cover grids 81266 in correct position Push connecting rods 81269 through lugs of cover grids 81266 CAUTION If the connecting rods 81269 are not correctly positioned in their re cesses on the filter silencer unit 81135 the cover grid 81266 can twist a...

Page 59: ... 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 Screw lock nuts 81273 onto screw 81272 and tighten to following torque Lock nut Tightening torque Nm 81273 40 Fit filter strip 81265 If provide...

Page 60: ...l mist or dust are in the intake air Consequences of contamination Impaired compressor efficiency Higher exhaust gas temperatures Increased fuel consumption Increased rotor unbalance Periodic cleaning of the compressor during operation prevents or delays a severe increase of the contamination It does not however replace the regular service work during which the turbocharger is completely disman tl...

Page 61: ...injection pipe fitted in the filter silenc er or the suction branch The water does not act as a solvent but the dirt deposit is removed by the mechanical impact of the droplets This is a very suitable process provid ed that the degree of contamination is not too high CAUTION Corrosion and deposits when cleaning Damage and impairment of turbocharger parts due to salt water and cooling water additiv...

Page 62: ...ol panel Compressor wet cleaning operation with XC2 Trigger water injection according to the specifications of the en ginebuilder The specified water pressure upstream of the connection to the turbo charger must be maintained Operate engine for at least five additional minutes after cleaning The cleaning process can be repeated up to two times How successful the cleaning was can be seen from the c...

Page 63: ...cess which has been tested and is recommended by ABB Turbo Systems the following pre requisites must be fulfilled Engine load 50 85 Start of cleaning cycle in accordance with following description for wet cleaning operation with XC3 Compressor wet cleaning procedure with XC3 It is mandatory to fulfil the operating condition prerequisites before cleaning compressors with XC3 Remove the sealing plug...

Page 64: ...een injected After cleaning wait at least 5 minutes to allow the turbocharger to dry NOTICE If the cleaning operation is not satisfactory it may be repeated up to two times If the cleaning results are still not satisfactory after three attempts and the engine values are also unsatisfactory we recommend that you have the turbocharger inspected and cleaned by an official ABB Turbocharg ing Service S...

Page 65: ...ght 2016 ABB All rights reserved December 2016 HZTL2464_EN Revision D Cleaning turbines and guide vanes during operation 5 4 NOTICE HFO applications The TPL65VA has not been released for HFO applications Wet clean ing of the turbine blades and guide vanes during operation is thus nei ther required nor planned 5 4 ...

Page 66: ...to mechanical damage The use of needle guns or other impact tools for example damages the components Depending on the specification nozzle rings have protec tive coatings which can also be damaged Only use soft tools such as scouring cloths brushes or wire brushes In the event of heavy contamination the cleaning methods described in this chapter such as soaking can be repeated until a satisfactory...

Page 67: ...the cleaning agent Cleaning agents which contain chlorine attack metals Use only pH neutral cleaning agents which do not attack metals Observe safety data sheet CAUTION Water and contamination in the cartridge group If water or contamination penetrates the cartridge group this can impair the function of the turbocharger and damage parts inside the cartridge group Make sure that no water or contami...

Page 68: ... cleaning the turbine are described in the following To soften the layers of contamination on the turbine the cartridge group can be submerged vertically in a tank with liquid The cartridge group must be rotated to do this Two cranes or chain blocks must be used for the rotating operation Suspending the chain block directly from the crane and rotating the car tridge group is not permitted because ...

Page 69: ...ecure two lifting loops with swivel lifting eyes in the lower push off threads and suspend from a second crane 3 Rotate cartridge group horizontally by lifting the second crane 4 When the cartridge group is horizontal secure one chain block from one of the upper push off threads using a swivel lifting eye and sus pend from the second crane 5 Tighten chain block until entire cartridge group is susp...

Page 70: ... The lifting gear must not touch the compressor wheel at any time during rotation 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 o...

Page 71: ... lifting eye and attach to the first crane 5 Tighten chain block 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 Use only pH neutral cleaning agents which do not attack metals Observe safety data sheet Fill the tank with soaking liquid Only immerse the cartridge g...

Page 72: ...in the cartridge group If water or contamination gets into the cartridge group the turbocharger function may be impaired and parts in the cartridge group may be dam aged Place cartridge group on suitable wooden or metal supports 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...

Page 73: ...buted residual contamination deposits lead to rotor unbalance This can result in bearing or turbocharger damage Remove all traces of contamination from the turbine After brushing off the contamination fill the tank with clean water not salt water Submerge the turbine of the cartridge group in clean water so that loose particles of contamination detach completely Lift the cartridge group Dry turbin...

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Page 75: ... charger Rotor unbalance Contact an ABB Turbocharging Service Station Damaged turbine or compressor Damaged bearing Rubbing of rotating parts Normal behaviour no malfunction Turbo charger Minor uniform wear around the periphery of rotor components caused by slight local rubbing of adjacent components is permis sible The compressor blades and turbine blades are then short ened somewhat Certain tole...

Page 76: ...d or periodic surging Possible damage to components such as the compressor wheel tur bine blades bearings and filter silencer Have the cause clarified immediately by an ABB Turbocharging ser vice station and rectified Have components inspected for damage and if necessary replaced by an ABB Turbocharging service station Sporadic surge blows Surging of the turbocharger can occur during certain opera...

Page 77: ...Turbo charger 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 Turbo charger Heavy contamination of the tur bine Clean it Damaged rotor components or bearing Contact an ABB Turbocharging Service Station Pipes Defects such as leaks in the exh...

Page 78: ...r it or contact the manufac turer Turbocharger Air starvation for example filter silencer clogged with dirt Clean it Compressor turbine contaminated Exhaust counterpressure too high Clean or repair the boiler or ex haust silencer Damaged or eroded turbine Contact an ABB Turbocharging Service Station Charge air cooler Cooler contaminated Clean it Cooling water volume too low Top up the water Entry ...

Page 79: ...g Replace the manometer Line to manometer leaking Repair the leak Contaminated filter silencer causing excessive loss of pres sure Clean it Compressor turbine contaminated Damaged compressor turbine Contact an ABB Turbocharging Service Station Exhaust counterpressure too high Clean or repair the boiler or ex haust silencer Charge air pressure too high Engine performance and engine speed unchanged ...

Page 80: ...ing run down Possible causes Elimination Turbo charger 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 Turbo charger Turbocharger contaminated Clean it Damaged bearing Contact an ABB Turbocharging Service Station Rubbing rotor Foreign object in turbocharg...

Page 81: ...cause problems for the evaluation electronics This problem is eliminated by removing the gasket Defective sensor Contact ABB Turbocharging service station Measured speeds too high Dirty sensor tip The sensor tip is magnetic and can thus at tract metal particles As a result the dis tance to the auxiliary bearing decreases which can lead to amplification of the noise component and consequently to fa...

Page 82: ... 2016 HZTL2464_EN Revision D Variable Turbine Geometry 6 6 Variable Turbine Geometry VTG not adjustable Possible causes Elimination Turbocharger Heavy turbine contamination Contact an ABB Turbocharging Service Station VTG bearing damaged Drive unit electrical components No drive energy Contact an ABB Turbocharging Service Station 6 6 ...

Page 83: ...vision D Removal and installation Turbocharger weights 7 1 Lifting gear with a sufficient load limit must be used for removing and in stalling the turbocharger The following weight specification is the heaviest variant possible This standard value may deviate from the data on the rating plate depending on the specification TPL65VA32 33 1210 7 7 1 Weight kg ...

Page 84: ... When the cartridge group the bearing casing or the turbocharger is fitted to the engine it must be en sured that the orifice plates that are specified for the turbocharger have been installed in the two oil inlet channels Check correct installation of oil orifice plates Unplug the cable connector on the speed sensor Remove the insulation at the suspension ribs TPL65 Version with compressor wheel ...

Page 85: ...ace a sling around the bearing casing Loosen the fixing screws at the foot Lift the turbocharger off the engine and set it down to one side WARNING Beware of tilting If support for the turbocharger is not provided or is inadequate the tur bocharger could tip over during installation or removal and cause a se rious or even fatal injury Support the turbocharger at a suitable point If possible secure...

Page 86: ...ring casing When the cartridge group the bearing casing or the turbocharger is fitted to the engine it must be en sured that the orifice plates that are specified for the turbocharger have been installed in the two oil inlet channels Check correct installation of oil orifice plates Adapt turbocharger to suit engine Tighten fixing screws in foot in accordance with engine builder s in structions Fas...

Page 87: ...itions for assembly ABB Turbo Systems recommends that the casing positions are marked before disassembling the turbocharger Identifying assembly devices Not all assembly devices are marked with a part number They can be identified using the tool list This list is enclosed in the toolbox WARNING Maintaining assembly devices Assembly devices must be checked for damage before and after use Visually c...

Page 88: ...tach turbochargers assemblies or individual components only to lifting gear which is in technically perfect condition and has sufficient load capacity Make sure the load is suspended properly on the crane hook Do not let anyone stand beneath a suspended load Wear safety gloves against mechanical risks Wear safety helmet Definition of terms Suspension point Defined load carrying point on a componen...

Page 89: ...ghts of individual parts or assemblies are guides round ed off to the next highest value Assemblies Description TPL65VA32 33 01 Radial air suction branch 50 02 Axial air suction branch 35 03 Filter silencer 130 04 Compressor casing 180 05 Wall insert 40 06 Diffuser 19 07 Cartridge group 290 08 Turbine diffuser 30 09 Variable turbine geometry module 55 10 Radial gas inlet casing 50 8 2 Weights kg ...

Page 90: ...e 88 Copyright 2016 ABB All rights reserved December 2016 HZTL2464_EN Revision D Complete compressor casing TPL65VA32 33 240 NOTICE The total weight of the complete compressor casing is an addition of the weights of the compressor casing the diffuser and the wall insert Weight kg ...

Page 91: ... Removing and fitting filter silencer or air suc tion branch 8 3 Remove insulation where necessary Pass lifting gear through rib on filter silencer Pass lifting gear through lugs on back Unscrew nuts 72027 and remove them together with washers 72018 Remove filter silencer and set it down to one side Install filter silencer in reverse order 8 3 Removing the filter silencer Installing the filter sil...

Page 92: ...uilder s instruc tions Dismantle the insulation where necessary Pass a lifting gear around the air suction branch It is permissible to pass the lifting gear through holes possibly provided in the ribs to im prove stability Unscrew the nuts 72027 and remove them together with the washers 72018 Remove the air suction branch and set it down to one side Fit the air suction branch in reverse order Remo...

Page 93: ...lt in injury Wear safety gloves Wear safety gloves against mechanical risks The axial clearance A must be measured before removing and after fitting the cartridge group Measure and note the axial clearance A TPL65VA32 33 0 31 0 49 CAUTION Clearances out of tolerance Clearances out of tolerance and excessively worn components can be the cause of serious damage to machinery and property Have compone...

Page 94: ...o oil inlet channels in the bearing casing When the cartridge group the bearing casing or the turbocharger is fitted to the engine it must be en sured that the orifice plates that are specified for the turbocharger have been installed in the two oil inlet channels Check correct installation of oil orifice plates Loosen and remove sealing air line 56501 between compressor cas ing 72000 and variable...

Page 95: ...with the wall insert and diffuser and set them down with surface F on an underlay WARNING Tipping the compressor casing Make sure the underlay does not shift Allow the compressor casing to rest only on surface F Check the underlay and adjust it if necessary Remove the screws 72002 Remove the diffuser 79000 Remove the wall insert 77000 using swivel lifting eyes 90235 Remove the O ring 77005 from th...

Page 96: ...e O ring 42012 Remove the three screws 61059 together with their Verbus Ripp washers 61058 Attach one lifting gear each to the two fins of the bearing casing pro vided for this purpose Evenly press off cartridge group by screwing press off screws 90900 into the designated holes CAUTION If the rotor blades have insufficient or no clearance the blades and cas ing could be damaged Check that the blad...

Page 97: ...ge group 8 5 Page 95 Copyright 2016 ABB All rights reserved December 2016 HZTL2464_EN Revision D Withdraw cartridge group and fit supports 90450 Remove screws 42054 together with flange 42044 and also remove possible contamination behind the flange Cover the oil connections ...

Page 98: ...urbine diffuser 8 6 Replace two screws 61032 with two studs 90903 in upper section of turbine diffuser Screw out the remaining screws 61032 press off the turbine diffuser 63000 using the press off screws 90901 then withdraw and re move it Fitting the turbine diffuser Fit the turbine diffuser in reverse order of removal NOTICE Brush high temperature grease on all screws at and in the gas outlet cas...

Page 99: ...t casing 51001 together with variable turbine geom etry module 56100 CAUTION After removing screws 56122 and retaining clips 56121 gas inlet casing 51001 is no longer secured Loosen screws 56122 together with retaining clips 56121 and re move with clamping ring 56112 Remove clamping ring 56112 Carefully separate gas inlet casing 51001 from variable turbine ge ometry module 56100 and remove it CAUT...

Page 100: ...L2464_EN Revision D Fitting the variable turbine geometry module and the gas inlet casing 8 8 Push variable turbine geometry module 56100 over studs Push gas inlet casing 56001 over studs Slide clamping ring 56112 onto studs Tighten nuts 61042 to specified torque Fit retaining clips 56121 using screws 56122 Fit semi circular section of sealing air line A to variable turbine ge ometry module 8 8 ...

Page 101: ...mbly and assembly 8 Fitting the variable turbine geometry module and the gas inlet casing 8 8 Page 99 Copyright 2016 ABB All rights reserved December 2016 HZTL2464_EN Revision D Fit sealing air line 56501 to semi circular section of line A ...

Page 102: ...he bearing casing or the turbocharger is fitted to the engine it must be en sured that the orifice plates that are specified for the turbocharger have been installed in the two oil inlet channels Check correct installation of oil orifice plates Remove the cover from the oil connection Fit flange 42044 with screws 42054 and new gasket 42045 Attach one lifting gear each to the two fins of the bearin...

Page 103: ... be damaged Check that the blades do not rub on the turbine diffuser by rotating the rotor Remove the lifting gear Fit O ring 42012 Screw in the speed sensor 86505 together with the O ring 86506 and plug in the cable connector 86515 Fit the O ring 77005 to the wall insert 77000 Fit the lifting gear and the swivel lifting eye 90235 Align and fit the wall insert 77000 using the centring screw 90187 ...

Page 104: ...ess off nuts 61090 onto bearing casing studs equally spaced around circumference and up to end of thread Push compressor casing 72000 onto cartridge group to fit snugly and fasten it using nuts 61037 Secure three press off nuts 61090 against compressor casing 72000 by tightening them to specified torque See chapter Table of tightening torques Remove lifting device 90190 Fit sealing air line 56501 ...

Page 105: ...ances out of tolerance and excessively worn components can be the cause of serious damage to machinery and property Have components assessed and if necessary replaced by an ABB Turbocharging Service Station Connect oil lines and all air lines in accordance with engine builder s instructions Version with compressor wheel cooling system Fit the air supply line Also see the chapter Preliminary remark...

Page 106: ...tion Manual TPL65VA32 33 Disassembly and assembly 8 Table of tightening torques 8 10 Page 104 Copyright 2016 ABB All rights reserved December 2016 HZTL2464_EN Revision D Table of tightening torques 8 10 8 10 ...

Page 107: ... D Part number TPL65VA32 33 01 82005 M16x1 5 50 03 72027 With washer M14 100 04 72002 M10 50 06 61037 M14 80 07 61090 M14 10 08 61036 61041 72029 M14 50 09 61059 M14 160 13 42059 42064 M12 50 17 61056 M14 150 18 51075 56110 56114 M8 25 19 61042 M14 130 24 56122 M10 50 30 86505 M18x1 5 160 Part number TPL65VA32 33 29 56501 M26x1 5 30 Tightening torques Nm Tightening angle ...

Page 108: ......

Page 109: ...ise the alarm and depending on the situation stop the engine Seal the oil leak Soak up oil and dispose of in an environmentally compatible manner Wear safety gloves against thermal risks CAUTION Directives for taking out of operation Serious damage to engine or property can be caused by non compliance with the directives for locking blanking off the turbocharger on the engine Follow the directives...

Page 110: ...vision D Fit cover plate 9 2 NOTICE The cover plate material General structural steel in accordance with DIN EN 10025 2 must be manufactured in house according to the drawing Product B1 B2 B3 B4 B5 B6 B7 B8 TPL65 13 325 30 30 8 10 6 70 Product Ø 1 Ø 2 Ø 3 Ø 4 Ø 5 Ø 6 TPL65 616 694 660 16 22 15 Product α 1 α 2 α 3 TPL65 4 x 90 37 5 24 x 15 9 2 Cover plate dimensions mm ...

Page 111: ... out of operation at short notice 9 Fit cover plate 9 2 Page 109 Copyright 2016 ABB All rights reserved December 2016 HZTL2464_EN Revision D NOTICE Carry out the work as described in the chapter Removal and fitting Remove cartridge group ...

Page 112: ...over plate 9 2 Page 110 Copyright 2016 ABB All rights reserved December 2016 HZTL2464_EN Revision D Close off opening in gas outlet casing using cover plate Fasten cover plate using spacer sleeves and nuts 61037 CAUTION Shut off the supply of lubricating oil to the turbocharger ...

Page 113: ... builder s instructions 4 stroke engine with several turbochargers No further measures are necessary on engines with separate air and ex haust gas receivers The engine can be operated as a naturally aspirated engine according to the engine builder s instructions The air line must be closed off at the engine end because the undamaged turbochargers build up a receiver pressure CAUTION The engine can...

Page 114: ...urbocharger Shut off compressor casing outlet gas inlet and gas outlet by fitting cover plates NOTICE In this respect refer to the engine manufacturer s instructions Bypass the turbocharger 9 4 CAUTION Shut off the lubricating oil supply to the turbocharger This applies to engines with one turbocharger only The connections are ready and pipes for the bypass are available Fit bypass around turbocha...

Page 115: ... by preserving oil before taking the engine out of operation and this is circulated by the pre lubrication pump no measures have to be taken Any remaining old engine oil will therefore be flushed away and the bearing sections largely protected against corrosion Mothballing measures WARNING Handling operating materials and supplies Swallowing or inhaling vapours of operating materials and supplies ...

Page 116: ...re necessary after taking an engine out of opera tion Dismantle the turbocharger The rotor and the bearing parts must be removed by an official ABB Turbocharging service station and refitted afterwards Clean all parts Machined bright surfaces of steel and cast parts must be oiled with anticorrosive oil Reassemble complete turbocharger Rotor turning in stack draught If the rotor turns as a result o...

Page 117: ...in indi vidual parts See the section Taking out of operation for up to 12 months under Moth balling measures for the measures always necessary when mothballing turbocharger parts If the turbocharger remains mounted on the engine refer to the section Taking out of operation for up to 12 months under Rotating the rotor in stack draught If the entire turbocharger is removed or if the turbocharger is ...

Page 118: ......

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

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Page 121: ...en into consideration in this document please contact an ABB Turbocharging Service Station CAUTION Storage of spare parts All spare parts ordered with the turbocharger must be kept complete and ready for use Parts showing signs of rust should be carefully cleaned and greased Dispose of replaced and unusable parts in a professional and envi ronmentally compatible way Required customer spare part se...

Page 122: ...Manual TPL65VA32 33 Spare parts 12 View of turbocharger with part numbers 12 2 Page 120 Copyright 2016 ABB All rights reserved December 2016 HZTL2464_EN Revision D View of turbocharger with part numbers 12 2 12 2 ...

Page 123: ...on nut 61043 in customer spare parts set Verbus Ripp Washer 61044 in customer spare parts set Hexagon head screw 61056 in customer spare parts set Hexagon head screw 61057 in customer spare parts set Verbus Ripp Washer 61058 in customer spare parts set Verbus Ripp Washer 61059 in customer spare parts set Hexagon head screw 63000 Turbine diffuser 68000 Foot 72000 Compressor casing 72018 Washer 7202...

Page 124: ...ABB Turbo Systems AG Bruggerstrasse 71a CH 5400 Baden Switzerland ABB ...

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