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Operation Manual / TPS44-F.. - TPS61-F..

6 Troubleshooting / 6.2 Surging of the turbocharger

© Copyright 2020 . All rights reserved.

HZTL2412_EN

Rev.G

March 2020

6.2 Surging of the turbocharger

Turbocharger surging

Possible causes

Elimination

Engine

Guard in front of the tur-
bocharger is contaminated
or damaged

Clean / replace it

Turbocharger Filter silencer or diffuser

contaminated

Clean it

Heavy deposits of dirt in the
turbine or nozzle ring

Charge air
cooler

Cooler contaminated

Clean it

Charge air duct blocked

CAUTION

Prolonged or periodic 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 condi-
tions such as when reducing the engine performance quickly when man-
oeuvring. At the same time, the flow direction in the compressor is mo-
mentarily reversed. Such sporadic surge blows do not impair the safe
operation of the turbocharger.

¡

A surge blow is accompanied by a loud bang and escape of hot air
from the filter silencer.

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Summary of Contents for HT596383

Page 1: ... Turbocharging Type TPS44 F31 HT596383 nMmax 1207 t Mmax 680 nBmax 1147 t Bmax 650 1 s C SSTI01 00120 16 60 60 Year 2020 Application according to the Operation Manual kg HZTL2412 English TPS44 F31 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: ... 15 2 4 Definition of Safety instructions 15 2 5 Warning plates on the turbocharger 16 2 6 Safe operation and maintenance 16 2 7 Hazards during operation and maintenance 20 2 8 Deflagration on gas engines 25 2 9 Periodic checking of the pressure vessel 26 2 10 Lifting loads 26 3 Start up 28 3 1 Oil supply 28 3 2 Inspection work 32 3 3 Commissioning after taking out of operation 34 4 Operation 35 4...

Page 4: ...bly and assembly 78 8 1 Introduction 78 8 2 Module weights 81 8 3 Disassembling and assembling turbocharger 82 8 4 Axial clearance A and radial clearance B 96 8 5 Radial clearances N and R 98 8 6 Table of tightening torques 100 9 Taking out of operation 101 9 1 Shutting down the turbocharger 101 10 Mothballing the turbocharger 105 10 1 Taking the engine out of operation for up to 12 months 105 10 ...

Page 5: ...ow to use it as intended It provides important information in order that the turbocharger can be operated safely correctly and efficiently This Operation Manual complements and expands existing national reg ulations concerning work safety and accident prevention Target group This Operation Manual is intended for engineers and qualified mechan ics who are responsible for operating the engine and th...

Page 6: ... March 2020 1 2 Layout and function 1Suction branch filter silencer 8Gas outlet flange 2Compressor casing 9Nozzle ring 3Diffuser 10Turbine casing 4Bearing casing 11Turbine end bearing flange 5Axial thrust bearing 12Compressor end bearing flange 6Radial plain bearing visible only at turbine end 13Compressor wheel 7Turbine Page 4 113 ...

Page 7: ...t gases escape into the ambient air through the exhaust gas pipe which is connected to the gas outlet flange 8 The air which is necessary for operation of the diesel or gas engine and is compressed in the turbocharger is drawn into the compressor wheel 13 through the suction branch or filter silencer 1 It then passes through the diffuser 3 and leaves the turbocharger through the outlet on the comp...

Page 8: ...ther type of use If the equipment is used for any other purpose ABB Turbocharging reserves the right to reject all warranty claims State of the art 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 o...

Page 9: ...rotection of health 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 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 t...

Page 10: ...ed In this case the turbochar ger must be inspected by an ABB Turbocharging Service Station and repacked u Inspect the package for damage If the package is damaged the tur bocharger must be inspected by an ABB Turbocharging Service Sta tion and repacked After every 3 years the following work steps must be performed by an ABB Turbocharging Service Station Inspect the component Replace the desiccant...

Page 11: ... 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 If the turbocharger shows modifications affecting safety or any cor responding operating behaviour it must be shut down immediately by stopping the engine The malfunction must be repor...

Page 12: ...e 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 pr...

Page 13: ...cilitate the work on the 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 com plied with Definition of caution warning The caution and warning signs are described in the chapter Safety ABB Turbocharging ABB Switzerland Ltd Turbocharging is identified as ABB Turbocharging in this...

Page 14: ...th the enginebuilder 02 Turbocharger operating limits during operation Recommended inspection and replacement intervals for turbocharger compon ents 03 Inspection 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 ...

Page 15: ... official ABB Turbocharging service station nMmaxand tMmax normally apply only when running at overload 110 during trials on the engine test bed Operation above nMmax and tMmax is not permit ted Non observance of the recommended replacement intervals increases the risk of unpredictable component failures 1 7 2 Positions of the rating plates One rating plate 01 each is attached on the left and the ...

Page 16: ... 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 and...

Page 17: ...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 signs...

Page 18: ... Service Stations u Remove unreadable warning plates u Clean and degrease surfaces provided for warning plates u Attach new warning plates Uninsulated turbochargers When uninsulated turbochargers are delivered to the engine builder the warning plates must be subsequently attached to the insulation This is the responsibility of the engine builder 2 6 Safe operation and maintenance The instructions ...

Page 19: ... ma terials that are in perfect condition u Electric tools must be solidly earthed and connecting cables may not be damaged u Keep the workplace clean clear away loose objects and remove obstacles on the floor u Keep the floor equipment and the turbocharger clean u Have oil binding materials ready at hand and keep oil catch pans ready or in position u Eliminate leaks u Keep fire protection materia...

Page 20: ... u Before starting work carry out visual inspection of working area u Remove any obstacles and objects lying around u Before start up commissioning check all pipes from and to tur bocharger for damage and leaks u Don t work in any way that could impair safety when working on tur bocharger u After about every 12 hours of operation or at least once a day inspect turbocharger for visible damage and d...

Page 21: ...ust have come to a standstill u Ensure that 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 ...

Page 22: ...harger 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 hazar...

Page 23: ...5 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 WARNIN...

Page 24: ...ger surfaces is compuls ory Wear safety gloves to protect against thermal hazards Hazards due to operating and auxiliary materials Operating and auxiliary materials are substances used for operation or the execution of maintenance work Oils greases coolants cleaning agents and solvents acids etc can be regarded as hazardous materials Operating and auxiliary materials can be combustible and easily ...

Page 25: ...mination of the ground and water due to improper disposal can lead to environmental damage u Handle operating and auxiliary materials carefully u Heed the instructions for use safety data sheets and hazard notices on the containers of the operating and auxiliary materials u Wear appropriate protective clothing u Avoid inhalation and contact with the skin u Ensure that the work space is adequately ...

Page 26: ...a 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 work ...

Page 27: ...urbochargers can withstand a deflagration with a transient pres sure increase of 12 bar ABB Turbocharging recommends that following a deflagration event the turbocharger undergoes an inspection of the following points Position of the turbine and compressor casings to the bearing casing Shifting of the bearing casing in relation to the bracket Cracks in casings If during external inspection anomali...

Page 28: ...erating company must make sure the pressure vessels are in proper working condition and monitor them Necessary repair or main tenance work must be carried out without delay and the required safety precautions must be taken u Pressure equipment must not be operated if it has defects 2 10 Lifting loads WARNING Suspended loads Loads not suspended in compliance with regulations may lead to per sonal i...

Page 29: ...oading 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 remove...

Page 30: ...pending on the turbine specifications and bearings used varying amounts of contaminants have to be filtered out of the lubricating oil to avoid dangerous wear of the bearing parts The standard oil filter specification for the turbocharger is 34 µm This means that contaminants larger than 0 034 mm must be filtered out of the oil with a separation efficiency 99 u Fit an accessory filter if engine oi...

Page 31: ...viscosities and oil inlet temperatures are shown in the following chart 1 Kinematic viscosity mm2 s cSt 2 Oil inlet temperature C A Permissible range CAUTION Falling below the minimum oil inlet temperature Serious machine or property damage can be caused by excessively high oil viscosity and the resulting lack of oil in the bearings u Do not allow the oil inlet temperature to fall below the minimu...

Page 32: ...e operation Status for operation Oil pressure in front of turbocharger bar Normal operation 2 0 4 5 Engine start cold oil permissible for maximum 15 minutes 8 0 Engine idling 0 2 Pre and post lubrication engine stopped 1 0 CAUTION Prelubrication Serious machine or property damage might result if the turbocharger is not supplied with oil when the engine is starting u Activate prelubrication device ...

Page 33: ...l temperature at the outlet depends mainly on lubricating oil temperature and pressure at the oil inlet engine load and turbocharger speed exhaust gas temperature The maximum permissible oil temperature at the outlet is listed in the following table The specified oil outlet temperature must be regarded as an alarm value for turbocharger operation and be monitored in ac cordance with standard regul...

Page 34: ...inated oil Particles of dirt and solid matter in the oil can cause serious damage to the machine or property u During initial commissioning and after all service work the complete lubricating system must be flushed thoroughly with warm oil u When running in the engine and after all service work on the lubricat ing system special running in filters must be used u Check oil pressure in oil supply li...

Page 35: ...erature in front of and behind turbine u Measure air temperature in front of and behind compressor The measured values must be compared with the values in the accept ance test report while taking different operating conditions into ac count NOTICE Lubricants and pastes used during assembly of the turbocharger li quefy or vaporise and might escape as an oily liquid in the first few hours after comm...

Page 36: ...efore gas inlet and after gas outlet u Inspect exhaust gas duct line in front of and after turbine for any combustion deposits foreign matter or residual water Clean and re move u Inspect air supply line or filter silencer for any foreign matter Clean and remove u Start up turbocharger oil circulation system at engine end u Prepare turbocharger for operation as instructed in section Inspec tion wo...

Page 37: ...charger The highest sound pressure level of emissions1 reaches a maximum of 105 dB A near the filter silencer and over the entire speed range The following prerequisites must be fulfilled on the turbocharger in or der to observe this limit value Fitted air inlet system All standard noise reducing measures have been taken2 The bellows at the air outlet have been perfectly insulated acoustic ally by...

Page 38: ...anges to the turbocharger to be identified and rectified In this way it can be ensured that the turbocharger remains in full work ing order CAUTION Service intervals Service work on the turbocharger that is neglected or carried out too late can lead to excessive contamination and wear as well as operating failures u Carry out service work at specified time intervals CAUTION Shortened service inter...

Page 39: ...rvice work every 25 50 hours u Visual inspection for air exhaust gas water and oil leaks u Record operating data and enter it in the engine logbook u Clarify the cause of any variances CAUTION Unknown changes during operation The consequences can range from an impairment to a breakdown u Have unknown causes clarified by an ABB Turbocharging service sta tion 4 2 2 Servicing work according to the en...

Page 40: ...m for cracks and erosion corrosion u Clean bearing casing and blow air through oil ports holes u Clean nozzle ring and check for cracks and erosion 4 2 4 Entries in engine logbook By monitoring the engine conclusions can be drawn about the tur bocharger performance The following operating data and measured values must be entered reg ularly in the engine manufacturer s engine logbook Engine perform...

Page 41: ...acement interval for those non rotating components that are exposed to hot gases Decisive in this respect are various influencing parameters which can drastically shorten the replacement intervals of these parts in extreme cases During the specified periodic service work the individual components are inspected for wear and if necessary replaced Expected replacement intervals h GAS MDO HFO Turbine ...

Page 42: ...uences Fuel quality and preparation Load profile thermal load cycles also starts stops emergency shut downs Gas inlet temperature Frequency and execution of turbine and compressor cleaning Turbocharger specification System specific operating conditions operating point combustion quality composition of exhaust gas For bearing parts Lubricating oil quality oil filtration condition of lubricating oil...

Page 43: ... 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 86505 A Speed sensor cable not integ rated 86526F I converter 86505 B Speed sensor cable integrated 86528Tachometer 86515 A Cable connector to 86505 A 01Screw plug 86515 B Cable connector to 86505 B 02Gasket ...

Page 44: ... 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 tur ...

Page 45: ...00 C u Wear safety gloves when removing the cable connector and speed sensor Wear safety gloves to protect against thermal hazards u Reduce engine performance to the idling speed then 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 up to the limit bloc...

Page 46: ... system are de scribed in the chapter Troubleshooting 4 5 Stopping the engine CAUTION Stopping the engine of oil cooled turbocharger version Heat in the turbocharger must be dissipated by the further circulating lubricating oil u Post lubricate for 15 20 minutes u Maintain oil pressure of 0 5 1 0 bar for post lubrication CAUTION Stopping the engine of water cooled turbocharger version Heat in the ...

Page 47: ...ing If mechanical cleaning is carried out too often this can lead to damage and corrosion on the components u If cleaning during operation is not sufficient to achieve acceptable values regarding thermal load and engine performance mechanical cleaning of certain spots can be carried out u Perform mechanical cleaning especially of the cartridge group only once within the service interval To allow y...

Page 48: ...n 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 turbocharger is completely dis mantled and the compressor is cleaned mechanically NOTICE If the coating of dirt is very thick and hard the compressor can only be cleaned manually when disassembl...

Page 49: ...nation 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 The injection pipe must on no account be connected directly via a cock to a water pipe or a dosing vessel larger than the one supplied This prevents uncontrolled volumes o...

Page 50: ...ter from the externally mounted water vessel is suitable only for those applications where a negative pressure exists in front of the compressor wheel not used for blowers connected in front of the compressor or high pressure compressor stages with two stage char ging Operating state prerequisites for cleaning compressor with XC1 NOTICE To be able to carry out a satisfactory cleaning process which...

Page 51: ...ected u Do not repeat the cleaning cycle until a stabilisation period of at least 10 minutes has elapsed NOTICE Whether or not cleaning has been successful can be seen from the char ging or flushing pressure and also from the exhaust gas temperatures If the cleaning process is unsatisfactory it can be repeated up to 2 times If the cleaning result is still not satisfactory after three attempts and ...

Page 52: ... that the intervals between overhauls can be extended if cleaning while in operation is car ried out periodically Wet cleaning the turbine as described below should be used for 4 stroke applications when there are heavy deposits from for example HFO Under no circumstances is periodic cleaning of the turbine during opera tion a substitute for the service work carried out when the turbocharger is co...

Page 53: ...ing methods Process with short water injection time 3 x 30 seconds cleaning The cleaning process with short water injection time is used for tur bocharger designs without additional sealing by means of C rings The process is based on the principle of thermal shock in combination with a subsequent flushing phase Process with long water injection time 10 minutes cleaning The cleaning process with a ...

Page 54: ...nsideration when setting the operating point before cleaning u Don t exceed maximum temperature in front of turbine when clean ing CAUTION Impermissible thermal stressing and flooding of the turbine Smaller volumes of water can result in poor cleaning Larger volumes of water lead to impermissible thermal stressing of the turbine compon ents and can cause flooding of the turbine u Be absolutely sur...

Page 55: ... 2020 Characteristic com ponent Conditions short Water injection time long Water injection time Water supply ensured Water pressure overpres sure over atmosphere pWT 2 0 bar 1 5 bar If necessary engine performance must be reduced to maintain these conditions The cleaning cycle can now be started based on the following descrip tion Page 53 113 ...

Page 56: ...mpletes the turbine cleaning process Cleaning parameters during the process TPS Temperature in front of the tur bine during clean ing C Water volume flow 1 dm3 min Injection time min Pause between injec tions min 44 450 4 5 0 5 3 x 3 48 6 52 8 57 11 61 17 5 1 corresponds to a water pressure pWT of 2 0 bar overpressure over at mosphere CAUTION Maximum temperature in front of turbine during cleaning...

Page 57: ...process TPS Temperature in front of the tur bine during cleaning C Water volume flow 1 dm3 min Injection time min Stabilising phase before after wa ter injection min 44 530 2 5 10 10 48 4 52 5 5 57 8 5 61 12 1 corresponds to a water pressure pWT of 1 5 bar overpressure over at mosphere CAUTION Maximum temperature in front of turbine during cleaning When cleaning the temperature in front of the tur...

Page 58: ...cation nozzle rings and turbine casings have protective coatings which can also be damaged u Only use soft tools such as cloths brushes or wire brushes u In the event of heavy contamination the cleaning methods that have been described such as soaking can be repeated until a satisfactory result has been achieved u Dispose of dirty water and cleaning agents in an environmentally compatible manner p...

Page 59: ...d u Remove filter ring 81265 u Clean filter ring 81265 as required or every 500 operating hours and replace after the fifth cleaning operation at the latest The degree of contamination of the filter ring depends on the cleanli ness of the air that is drawn in u Wash filter ring 81265 using water containing light duty detergent or if very heavily contaminated soak it while squeezing carefully Rinse...

Page 60: ...d air soft brush or a damp cloth u Have absorption segments which are heavily contaminated replaced by an official ABB Turbocharging Service Station Fitting the filter silencer u Insert the absorption segments 81136 into the sheet metal cover ings 81137 u Bend the sheet metal coverings 81137 back into their original shape and insert them into the slot guides in the silencer body 81135 u Fit the co...

Page 61: ...tive equipment PPE according to the material safety data sheet u Comply with local legislation Wear safety goggles Wear safety gloves to protect against chemical hazards Wear a respiratory mask to protect against gases The following performance relevant parts can be cleaned according to the following description 72000 Compressor casing 77000 Wall insert 79000 Diffuser u Clean the components specif...

Page 62: ...ety 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 51000 Turbine casing 56001 Nozzle ring 52400 Gas outlet flange u Place contaminated parts in hot water or ...

Page 63: ...r cleaning Compressor wheels or turbines may be heavily contaminated due to ex haust gas deposits or coked oil Such contamination may possibly no longer be removed through cleaning during operation and must be cleaned mechanically during the standard service intervals see chapter entitled Service work u Remove turbocharger from the engine see chapter Removal and in stallation 74 u Remove cartridge...

Page 64: ...artridge 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 group u Clean compressor wheel with a cloth or soft brush soaked in water with household detergent Do not use any wire brushes u Dry the compressor wheel and th...

Page 65: ...A mm B mm C mm TPS44 91 15 173 TPS48 108 17 205 TPS52 128 20 245 TPS57 157 25 300 TPS61 187 30 357 To soak the layers of dirt on the turbine the cartridge group can be sub merged vertically in a tank 02 with liquid u Place the tank 02 in a larger container 03 so that the excess liquid can be collected CAUTION Selection of the cleaning agent Cleaning agents which contain chlorine attack metals u Us...

Page 66: ...the information in the material safety data sheet Wear a respiratory mask according to material safety data sheet CAUTION Water and dirt in the cartridge group If water or dirt gets into the cartridge group the turbocharger function may be impaired and parts in the cartridge group may be damaged u Place the cartridge group on suitable wooden or metal supports 01 u Maintain dimension B for the supp...

Page 67: ...atory tract this can be harmful to health u Avoid the formation of dust u Vacuum up dust with a suitable vacuum cleaner u Wear a respiratory mask to protect against particles P1 or P2 mask u Wear safety goggles Wear safety goggles Wear a respiratory mask to protect against dusts Wear safety gloves to protect against mechanical hazards u Raise the cartridge group and align horizontally u Remove dir...

Page 68: ...otor un balance 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 02 with clean wa ter not salt water u Submerge the turbine of the cartridge group in clean water so that loose particles of dirt detach completely u Raise the cartridge group and align horizontally u Clamp the partition wall wi...

Page 69: ...tor unbalance Contact an ABB Turbocharging Service Station Damaged turbine or com pressor Damaged bearing Rubbing of rotating parts Normal behaviour no malfunction Turbochar ger Minor uniform wear around the periphery of rotor components caused by slight local rubbing of adjacent components is per missible The compressor blades and turbine blades are then shortened somewhat Certain tolerances must...

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

Page 71: ...r 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 pip...

Page 72: ...ion 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 too...

Page 73: ...nometer 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 con...

Page 74: ...cording to instructions of enginebuilder Reduced fatigue strength of the compressor wheel compressor blade breakage Possible causes Elimination Turbochar ger Corroded compressor wheel material Check fuel and its corrosive con stituents and if necessary change fuel 6 4 Malfunctions when stopping Noises during run down Possible causes Elimination Turbochar ger Turbocharger contaminated Clean it Dama...

Page 75: ... for the evaluation elec tronics This problem is eliminated by removing the gasket Defective sensor Contact an ABB Turbocharging Service Sta tion Measured speeds too high Contaminated sensor tip The sensor tip is magnetic and can thus at tract metal particles As a result the dis tance to the signal generating sealing disc is reduced which can lead to amplification of the noise component and conseq...

Page 76: ...ev G March 2020 7 Removal and installation 7 1 Transport Suspension of uninsulated turbocharger Turbocharger with oil cooled bearing casing Complete turbocharger with gas out let casing Suspension of insulated turbocharger Turbocharger with oil cooled bearing casing Complete turbocharger with gas out let casing Page 74 113 ...

Page 77: ...ct all exhaust gas and air lines according to the instructions of the enginebuilder Version with water cooled bearing casing u Disconnect the water pipes according to the instructions of the en ginebuilder If present remove hard insulation as follows u Remove screws and sheet metal B from the bearing casing insula tion u Remove the remaining screws from the bearing casing insulation A u Pull the b...

Page 78: ... the engine support the bolt threads and screw heads must be lightly oiled assumed friction coeffi cient µ 0 12 for tightening torque Strength class in accordance with DIN ISO 898 10 9 12 9 Product Through hole in bearing casing Thread size Tightening torque TPS44 17 mm M16 230 Nm TPS48 17 mm M16 230 Nm TPS52 21 mm M20 455 Nm TPS57 21 mm M20 455 Nm TPS61 25 mm M24 780 Nm u Attach lifting gear to b...

Page 79: ...in accordance with the engineb uilder s instructions If present u Fit speed sensor and plug in cable connector u Adapt and fit bearing casing insulation A u Adapt and fit sheet metal B of bearing casing insulation Version with water cooled bearing casing u Remove the screw plugs from the water connections and fit the water pipes in accordance with the enginebuilder s instructions Page 77 113 ...

Page 80: ...ion u Mark the casing position for assembly Identifying assembly devices Not all assembly devices are marked with a part number They can be identified using the tool list This list is enclosed in the toolbox WARNING Maintaining assembly devices Assembly devices must be checked for damage before and after use u Check visually for corrosion cracks deformation and wear u Don t use damaged assembly de...

Page 81: ...ion and has a suffi cient load limit u Make sure the load is suspended properly on the crane hook u Do not let anyone stand beneath a suspended load Wear safety gloves to protect against mechanical hazards Wear safety helmet Definition of terms Suspension point Defined load attachment point on a component or an assembly blind hole thread eye lug Assembly device Devices that are fitted on the turbo...

Page 82: ...ev G March 2020 Swivel lifting eye to be used A swivel lifting eye is required to lift loads safely not supplied by ABB Swivel lifting eye Product Thread M Length L Minimum load limit loading ca pacity TPS44 M8 13 mm 150 kg TPS48 M10 17 mm 250 kg TPS52 M10 17 mm 250 kg TPS57 M12 21 mm 350 kg TPS61 M12 21 mm 500 kg Page 80 113 ...

Page 83: ...S52 kg TPS57 kg TPS61 kg 1Filter silencer 15 19 30 40 65 2Radial air suction branch 5 6 8 11 21 3Axial air suction branch 3 4 4 6 9 4Compressor casing 17 24 35 55 90 5Wall insert 4 7 10 13 30 6Diffuser 2 2 3 6 10 7Cartridge group 25 35 50 85 140 8Nozzle ring 1 1 2 3 6 9Burst ring 1 2 3 5 12 10Turbine casing with external burst protec tion 1 inlet 30 35 50 80 130 2 inlets 30 35 50 90 150 3 inlets 5...

Page 84: ...rious burns u Do not touch hot surfaces and heed the warning plate on the tur bocharger u Wear heat resistant safety gloves and protective clothing u Allow the turbocharger to cool down before carrying out any work Wear safety gloves to protect against thermal hazards u Disconnect all air lines in accordance with the enginebuilder s instruc tions If provided u Remove the screws for the compressor ...

Page 85: ...arger Copyright 2020 All rights reserved HZTL2412_EN Rev G March 2020 Removing the insulation If provided u Loosen and remove the screws for the insulation plates 1 2 u If provided Remove the insulation plates 1 2 u Remove the remaining screws for the insulation 3 u Remove the insulation 3 Page 83 113 ...

Page 86: ...inst the turbine casing To do this the two cover plates 1 2 must be removed from the hard insula tion on the turbine casing CAUTION Axial force The press off tool can generate a high axial force and if it is not used properly too much pressure on one side it can damage the rotor u It should thus be used alternately on both sides while avoiding ex cessive pressure on either side u Loosen the screws...

Page 87: ... Fasten lifting beam 90258 to wall insert u Fasten swivel lifting eye a to lifting beam u Remove wall insert 77000 using lifting gear Disassembly of diffuser TPS F31 32 FV31 32 u Loosen screws 72041 and remove them together with lockwashers 72040 and diffuser 79000 from compressor casing 72000 Installing compressor casing u Refit wall insert 77000 and O ring 77005 in the reverse order Page 85 113 ...

Page 88: ...HZTL2412_EN Rev G March 2020 NOTICE O rings Used O rings must always be replaced with new ones O rings are only available as a set see chapter Spare parts Fitting the diffuser TPS F31 32 FV31 32 u Refit diffuser in reverse order u Fit compressor housing in reverse order u Thoroughly clean fastening strips 72012 before fitting them Page 86 113 ...

Page 89: ...ith hot operating materials can lead to serious burns u Do not touch hot surfaces and heed the warning plate on the tur bocharger u Wear heat resistant safety gloves and protective clothing u Allow the turbocharger to cool down before carrying out any work Wear safety gloves to protect against thermal hazards w The bearing casing is difficult to loosen u Use the press off tool 90042 against the tu...

Page 90: ...sing two extraction devices 90070 and withdraw bottom part of service support 90012 If provided u Remove C ring 51105 Disassembly of diffuser TPS F33 u Mount the cartridge group on the service support 90012 and bolt it down firmly u Loosen screw 42008 and remove diffuser 79000 complete with O ring 42012 u Measure the axial and radial clearances see the section Axial and ra dial clearances Page 88 ...

Page 91: ...shed back in with a screw driver u Fit the lamellar sealing ring 56005 if present in the correct slot see detail A When doing this pay attention to correct winding of the lamellar sealing ring see detail B u Secure the lamellar sealing ring with adhesive tape u Insert the nozzle ring 56001 with the cam facing forwards into the turbine casing as far as it will go Align the cam on the nozzle ring wi...

Page 92: ...held in place during operation it must be clamped between the partition wall and the turbine casing Nozzle ring press fit for single inlet turbine casing u Calculate the press fit PD as shown NOTICE If the calculated value PD is less than 0 1 mm an official ABB Tur bocharging Service Station must be contacted u Measure the axial and radial clearances see the section Axial and ra dial clearances Pa...

Page 93: ...d HZTL2412_EN Rev G March 2020 Nozzle ring press fit for multiple inlet turbine cas ing u Calculate the press fit PD as shown NOTICE If the calculated value PD is outside 0 2 mm an official ABB Tur bocharging Service Station must be contacted u Measure the axial and radial clearances see the section Axial and ra dial clearances Page 91 113 ...

Page 94: ...e support 90012 u Apply high temperature grease to the centering points and screw threads u Remove temporary covers from oil connections CAUTION Don t damage or shift gasket rings A in the mounting support when fitting the cartridge group The gasket rings A are supplied by the en gine builder NOTICE If two turbochargers are mounted on an engine one with a left hand and one with a right hand oil in...

Page 95: ...ng torques u Fasten the bearing casing 42001 using the fixing screws C u Tighten the fixing screws C to the torques listed in the following table For the assembly of the turbocharger on the engine support the threads of the screws and screw heads must be lightly oiled assumed coefficient of friction µ 0 12 for the tightening torque Product Hole in the bearing casing mm Fixing screws C mm Tightenin...

Page 96: ...provided fit the insulation plates 1 2 Removing gas outlet manifold and gas outlet flange If provided u Disconnect all lines in accordance with enginebuilder s instructions and remove insulation see also preceding chapter u Loop lifting gear around gas outlet manifold 51100 u Remove gas outlet manifold 51100 and gasket 52406 Only gas outlet manifolds from ABB have the gasket 52406 u Remove gas out...

Page 97: ...408 u Fit the gas outlet flange 52400 u For gas outlet manifolds 51100 from ABB always replace the gasket 52406 see the chapter entitled Spare parts u Apply high temperature grease to contacting surfaces and threads u Fit the turbine casing using the nuts 52433 while observing tighten ing torques specified in the table of tightening torques If provided u Fasten the insulation u Attach pipes in acc...

Page 98: ...e compressor wheel The compressor wheel has sharp edges which can cause injuries u Wear safety gloves Wear safety gloves to protect against mechanical hazards Axial clearance A and ra dial clearance B mm TPS44 TPS48 TPS52 TPS57 TPS61 A minimum 0 08 0 08 0 10 0 12 0 15 A maximum 0 16 0 16 0 18 0 21 0 25 B minimum 0 51 0 50 0 61 0 72 0 81 B maximum 1 00 1 00 1 15 1 31 1 55 Permissible B clearances f...

Page 99: ... stop are measured for the anticlockwise and clockwise rotations and then com pared With standard radial bearings the run out time for anticlockwise and clockwise rotating rotors is the same If one run out time is at least 1 5 times longer than the other then radial bearings with a special bearing geometry are installed The following B clearances are valid for these special bearings TPS57 TPS61 B ...

Page 100: ...inimum and maximum values result from the manufacturing toler ances of the compressor wheel and turbine wheel or the wall insert and gas outlet flange Feeler gauge N1 and N2 as well as R1 and R2 are each measured at the same time using two feeler gauges To measure N1 and N2 the feeler gauges must be pushed between the wall insert and the compressor wheel free of play in each case above and be low ...

Page 101: ...learance N and R Radial clearances N and R Product N mm R mm TPS44 0 15 0 49 0 36 0 67 TPS48 0 22 0 58 0 47 0 77 TPS52 0 30 0 67 0 59 0 92 TPS57 0 40 0 86 0 75 1 11 TPS61 0 50 0 94 0 90 1 32 CAUTION Clearances out of tolerance Clearances out of tolerance and excessively worn components can be the cause of serious damage to machinery and property u Have components assessed and if necessary replaced...

Page 102: ...lowing tightening torques must be observed for the specified bolted connections Tightening torques Nm Position Part num ber TPS44 TPS48 TPS52 TPS57 TPS61 1 72020 60 Nm 60 Nm 60 Nm 60 Nm 60 Nm 2 42008 6 Nm 10 Nm 10 Nm 20 Nm 40 Nm 5 52433 20 Nm 20 Nm 40 Nm 65 Nm 65 Nm 6 51007 25 Nm 25 Nm 45 Nm 75 Nm 75 Nm 9 72011 35 Nm 35 Nm 70 Nm 105 Nm 170 Nm 10 86505 15 Nm 15 Nm 15 Nm 15 Nm 15 Nm Page 100 113 ...

Page 103: ...bocharger is damaged and the engine can be shut down for only a short time for emergency repairs proceed as follows u Fit the cover plate CAUTION Always heed precisely the engine builder s instructions in case of en gine operation with a blocked throttled turbocharger Dismantling the turbocharger u Dismantle the turbocharger see the section Dismantling and fitting the turbocharger u Do not dismant...

Page 104: ... Close the opening in the turbine casing using the cover plate A u Fasten the cover plate on the turbine casing 51000 using the fasten ing strips 51002 Verbus Ripp Verbusripp washers 51003 and nuts 51007 and screw it down securely on the support NOTICE Thoroughly clean the fastening strips 51002 before fitting them Apply high temperature grease to the stud threads 51006 Page 102 113 ...

Page 105: ...llowing drawing Material Common structural steel in compliance with DIN EN 10025 2 Product B1 0 5 B2 B3 B4 0 2 B5 B6 TPS44 62 6 54 110 11 0 1 144 TPS48 65 7 60 130 11 7 1 5 150 TPS52 79 6 78 155 14 2 1 5 180 TPS57 98 2 100 190 17 2 2 220 TPS61 116 8 120 226 20 5 2 4 260 Product B7 ØD1 0 2 ØD1 0 2 ØD2 R1 M TPS44 191 3 191 3 17 88 M8 TPS48 35 7 222 7 227 7 17 105 M8 TPS52 39 6 265 7 271 7 21 125 M8 ...

Page 106: ...ocharger Copyright 2020 All rights reserved HZTL2412_EN Rev G March 2020 Diameter for turbine casing designs for optional C ring sealing NOTICE Information about the turbine casing design with without C ring sealing can be requested from an ABB Turbocharging Service Station Page 104 113 ...

Page 107: ...nd this is circulated by the pre lubrica tion 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 or contact with them may be harmful to health u Do not breath...

Page 108: ...than 12 months If the engine is taken out of operation the following variants are pos sible with regard to the turbocharger The turbocharger remains mounted on the engine The turbocharger casing remains mounted on the engine but the ro tor and the bearing parts are removed and stored separately by an ABB Turbocharging Service Station The turbocharger is removed completely either as a whole or in i...

Page 109: ...n for more than 12 months Copyright 2020 All rights reserved HZTL2412_EN Rev G March 2020 Condition of the mothballed turbocharger u Check the mothballed turbocharger parts for corrosion once per an num u If there are signs of rust Clean parts thoroughly and renew protection against corrosion Page 107 113 ...

Page 110: ...mask to protect against dusts Wear safety gloves to protect against mechanical hazards Disposal must be environmentally compatible professional and in com pliance with locally applicable regulations The turbocharger consists largely of metal cast iron materials steel nickel steel alloys aluminium and bearing brass Further components are Non metallic materials filter components of felt and polyethy...

Page 111: ...lease 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 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 Customer spare part set 97070 The customer spare part set 97070 is ...

Page 112: ... 12 Spare parts 12 2 View of turbocharger showing part numbers Copyright 2020 All rights reserved HZTL2412_EN Rev G March 2020 12 2 View of turbocharger showing part numbers only available in customer spare part set 97070 Page 110 113 ...

Page 113: ...01 Nozzle ring 57200 Burst protection 57210 Burst ring 72000 Compressor casing 72011 Socket screw 72012 Fastening strips 72020 V clamp 72041 in customer spare part set Counter sunk screw with cross slot ted head 77000 Wall insert 77005 in customer spare part set O ring 79000 Diffuser 81000 Filter silencer 81010 in customer spare part set O ring 82000 Axial air suction branch 82010 in customer spar...

Page 114: ...anual TPS44 F TPS61 F 12 Spare parts 12 3 View of cartridge group showing part numbers Copyright 2020 All rights reserved HZTL2412_EN Rev G March 2020 12 3 View of cartridge group showing part numbers Page 112 113 ...

Page 115: ...l 32101 Plain bearing bush 32103 Locking ring 32105 Thrust ring 32106 Thrust bearing 32108 Piston ring 32109 Sealing disc 32110 Bearing flange 32111 Auxiliary bearing 32112 Bearing flange 32113 Socket screw 32114 Socket screw 32221 Bearing cover 32222 O ring 42001 Bearing casing 42002 Socket screw 42008 in customer spare part set Socket screw 43001 Partition wall 43012 Metal C ring depends on the ...

Page 116: ...ABB Switzerland Ltd Turbocharging Bruggerstrasse 71a CH 5401 Baden Switzerland ...

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