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Operating limits and replacement intervals

The recommended replacement intervals and the corresponding operating limits in chapter 3 are jointly defined
with the enginebuilder. This information is specific to the product.

Non-observance of the recommended replacement intervals and the operating limits increases the risk of unpre-
dictable component failures.

Summary of Contents for HT600042

Page 1: ...Turbocharging Operation Manual TPS48 H33 HT600042 English Original Operation Manual Chapter Document ID 1 Introduction HZTL4005_EN_G 2 Safety HZTL4026_EN_D 3 Safety data sheet HT600042 4 Product descr...

Page 2: ...ls and the corresponding operating limits in chapter 3 are jointly defined with the enginebuilder This information is specific to the product Non observance of the recommended replacement intervals an...

Page 3: ...f contents Copyright 2020 ABB All rights reserved HZTL4005_EN Rev G March 2020 Introduction 1 Introduction 2 1 1 Purpose of the manual 2 1 2 Symbols definitions 3 1 3 Storage of new turbochargers and...

Page 4: ...lains the turbocharger and contains instructions for safe opera tion The Operation Manual is a complement to and expansion of existing national regulations for occupational safety accident prevention...

Page 5: ...the work 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 C...

Page 6: ...ctogram Meaning Tighten with specified torque Tighten over specified tightening angle Hand tight tighten without tools Oil Apply screw locking paste e g Loctite Apply high temperature grease Apply oth...

Page 7: ...the sense of the Hazardous Substances Ordinance Nevertheless the following points are to be observed when handling VCIs u Observe specifications in the safety data sheet u Ensure good room ventilation...

Page 8: ...the turbocharger must be inspected by an ABB Turbocharging Service Station and repacked u Inspect the package for damage If the package is damaged the turbocharger must be in spected by an ABB Turboch...

Page 9: ...reserved HZTL4005_EN Rev G March 2020 1 4 Contact information Contact information for the ABB Turbocharging Service Stations is available online u Scan the QR code to access our website ABB Switzerla...

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Page 11: ...datory signs 3 1 4 Definition of safety instructions 3 1 5 Intended use 4 1 6 Deflagration on gas engines 5 1 7 Warning plates on the turbocharger 6 1 8 Turbocharger rating plate 7 1 9 Periodic check...

Page 12: ...f insufficient compliance with safety instructions Are a consequence of insufficient or inappropriate performance of maintenance and in spection work The operating company is responsible for defining...

Page 13: ...sk to protect against Dusts Gases Safety helmet Ear protection Table 2 Personal protective equipment to be worn specific to the respective task 1 4 Definition of safety instructions WARNING Definition...

Page 14: ...required for operation The turbocharger is solely intended to be operated with a clockwise direction of rotation as viewed from the turbine end The specific operating limits of the turbocharger were...

Page 15: ...bocharger or improper operation 1 6 Deflagration on gas engines ABB turbochargers can tolerate a deflagration with a transient pressure increase of 12 bar After a deflagration event ABB Turbo Systems...

Page 16: ...always be present in the intended locations and must be legible Fig 1 Warning plate If warning plates are not present in the intended locations or are not legible they must be replaced with new warni...

Page 17: ...eed with the en ginebuilder 02 Turbocharger operating limits during operation Recommended inspection and replacement intervals of turbocharger components 03 Inspection interval of plain bearings in 10...

Page 18: ...ve nMmax and tMmax is not permitted Non observance of the recommended inspection and replacement intervals increases the risk of unpredictable component failures Locations of the rating plates The loc...

Page 19: ...nst mechanical hazards Wear safety helmet Fig 3 Attachment of loads on the crane hook Fig 4 Attachment angle If there are two or more suspension points the attachment angle of 45 must not be ex ceeded...

Page 20: ...ked periodically Suitable working materials and personal protective equipment must be kept in a perfect condition Only authorised personnel may remain in the vicinity of the turbocharger when the engi...

Page 21: ...nning always wear ear protection u Always wear ear protection if the sound pressure level exceeds 85 dB A Wear ear protection Hazards due to hot surfaces Surfaces of the turbocharger attached parts an...

Page 22: ...s to protect against thermal hazards Hazards due to rotating parts WARNING Physical hazards Contact with rotating parts can cause severe injury The turbocharger must never be used without the filter s...

Page 23: ...installations u Do not carry out any tests with regard to insulation resistance or voltage on the electrical components 1 13 Safe operation Mechanical hazards during operation During standard operatio...

Page 24: ...e received instruction or train ing Wear safety footwear to protect against mechanical hazard and risk of fall ing Wear protective clothing WARNING Risk of falling When working on the turbocharger the...

Page 25: ...uring disassembly assembly maintenance and repair u Observe the procedures for set up service and inspection work and the inspection inter vals u Inform the operating staff before starting any service...

Page 26: ...previously received instruc tion or training Hazards due to operating materials and supplies Operating materials and supplies are substances required for the operation of the tur bocharger or for the...

Page 27: ...the material safety data sheet for the operat ing materials and supplies u Comply with local legislation Hazards due to the handling of insulation materials WARNING Danger from insulation materials D...

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Page 29: ...ion Manual TPS48 H33 Safety data sheet Page 1 1 Safety data sheet Copyright 2021 ABB All rights reserved HT600042 April 2021 TPS48 H33 HT600042 TPS48 H33 HT600042 1018 680 996 650 12931342 180 16 60 6...

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Page 31: ...er 10 3 Commissioning 13 3 1 Oil supply 13 3 2 Inspection procedures 14 3 3 Commissioning after taking out of operation 16 4 Monitoring operation 17 4 1 Oil pressure oil temperature 17 4 2 Exhaust gas...

Page 32: ...ser 61 9 11 Installing the cartridge group 62 9 12 Installing nozzle ring 64 9 13 Fitting the turbine casing 65 9 14 Rotating the turbocharger 66 9 15 Radial clearances N and R 67 9 16 Installing the...

Page 33: ...y 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...

Page 34: ...s reserved HZTL4037_EN Revision E July 2017 1 4 Layout and function of the turbocharger Fig 1 Layout and function of the turbocharger 01 Air suction branch filter silencer 06 Plain bearing bush 02 Com...

Page 35: ...in air or a mixture of gas and air through the air suction branch 01 or the filter silencer In the compressor wheel 10 the energy required for build ing up the pressure is transferred to the air By fl...

Page 36: ...o the enginebuilder without insulation must be equipped later with warning plates on the insulation This is the responsibility of the enginebuilder If warning plates are not present in the designated...

Page 37: ...to the heaviest variant possible De pending on the specification the weight specified on the rating plate may be lower than the standard value specified here Product Weights kg TPS44 120 TPS48 180 TP...

Page 38: ...cool down before carrying out any work Wear safety gloves to protect against thermal hazards CAUTION Do not strain cables If you pull the speed measurement cables too hard contacts can be pulled out u...

Page 39: ...urbocharger This protects the plug from being crushed 4 Install the swivel lifting eye S and attach the lifting gear to it 5 Lift the turbocharger away from the support vertically The bracket turbocha...

Page 40: ...askets Gaskets that are forgotten damaged or improperly inserted will lead to oil leaks u Always use new gaskets and insert them carefully into the slot The oil is supplied 02 and drained 03 through t...

Page 41: ...cknuts 01 3 Remove nuts 01 again Requirements for the threaded rods 02 Fig 8 Requirements for threaded rods Product Diameter Threaded rod mm Material DIN ISO 898 Part 1 Thread length L1 mm Length of t...

Page 42: ...ater connections are removed 2 Make sure that the gaskets are not damaged and are positioned correctly in the slots 3 Install the swivel lifting eye S and attach the lifting gear to it 4 Align the tur...

Page 43: ...election of lubricating oil and the oil change intervals 3 1 2 Pre lubrication Pre lubrication must be carried out as follows u Switch on the oil pump u Build up oil pressure see Table 6 Lubricating o...

Page 44: ...Lubricating system CAUTION Contaminated oil Serious damage to engine or property can be caused by dirt and solid ma terial particles in the oil u For the initial commissioning phase and after all serv...

Page 45: ...ssible values Leaktightness of pipes WARNING Risk of burning from hot gas Escaping gases are hot and will lead to serious burns in the event of contact u Check all pipes for leaks in accordance with t...

Page 46: ...he locking screws on the water connections and fit the water pipe General u Check the exhaust gas pipe before and after the turbine for combustion residues or wa ter residues and clean it Remove any f...

Page 47: ...tur bocharger bar Normal operation 2 0 poil 4 5 Engine start Cold oil admissible for maximal 15 minutes 8 0 Engine idling admissible for maximal 1 hour 0 5 poil 2 5 Pre lubrication and post lubricatio...

Page 48: ...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...

Page 49: ...plate 4 3 Turbocharger speed 4 3 1 Introduction A speed measuring system enables the constant monitoring of the turbocharger speed CAUTION Do not strain cables If you pull the speed measurement cable...

Page 50: ...ZTL4037_EN Revision E July 2017 4 3 2 Layout and overview Fig 10 Layout and overview of the speed measurement system 86505 Speed sensor 42188 Screw plug 86515 Cable connector 42189 Gasket 86526 F I co...

Page 51: ...t be stopped it can continue to be driven at this reduced engine load or turbocharger speed u If a turbocharger surges continuously the engine performance must be reduced further u Measure the tempera...

Page 52: ...lip and an O ring No additional gasket is required during assembly Fig 11 Fitting the speed sensor Part number TPS44 TPS48 TPS52 86505 M12 x 1 5 15 Nm M12 x 1 5 15 Nm M12 x 1 5 15 Nm Table 9 Tightenin...

Page 53: ...t a distance of 1 meter from the turbocharger The highest value of the emission sound pressure level1 reaches a maximum of 105 dB A near the filter silencer The following prerequisites must be fulfill...

Page 54: ...pyright 2017 ABB All rights reserved HZTL4037_EN Revision E July 2017 Suggestion for noise insulation bellows Fig 12 Noise insulation bellows 01 Compressor casing 02 Bellows 03 Charge air duct scaveng...

Page 55: ...erformed too late can cause excessive contamination wear and operating failures u Carry out the service work at the specified time intervals CAUTION Shortened service intervals Exceptional stresses su...

Page 56: ...asured values must be entered every 24 48 hours in the engine logbook of the enginebuilder Performance and speed of the engine Air intake temperature Charging pressure Pressure loss in the charge air...

Page 57: ...sassembly of the cartridge group and assessment of the ro tor and bearing parts requires the specialist knowledge of an ABB Tur bocharging Service Station The rotor parts turn very fast and are very s...

Page 58: ...ed with the aid of the safety concept for rotating parts SIKO and dependent on the operating conditions Influencing parameters The specified values are guideline values and are not guaranteed The actu...

Page 59: ...re while performing post lubrication 0 5 poil 1 0 u Switch off post lubrication as soon as the rotor is stationary or after no more than two minutes Deviating procedures must be coordinated with ABB T...

Page 60: ...nd corrosion If mechanical cleaning is carried out incorrectly this can lead to damage and corrosion on the components u Pay attention to the specifications in this chapter pertaining to mechan ical c...

Page 61: ...ilter ring if present u Remove filter ring 81265 u Clean filter ring 81265 as required or every 500 hours of operation and replace after the fifth cleaning process at the latest Contamination of the f...

Page 62: ...ption segments 81136 must only be cleaned lightly with compressed air a soft brush or a moist cleaning cloth u Have any heavily contaminated absorption segments replaced by an ABB Turbocharging Servic...

Page 63: ...E 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 gase...

Page 64: ...omply with local legislation Wear safety goggles Wear safety gloves to protect against chemical hazards Wear a respiratory mask to protect against gases Baked layers of contamination for example from...

Page 65: ...emove cartridge group see chapter Dismantling and fitting 46 First clean the compressor end and then the turbine end according to the following descrip tion 7 2 6 Cleaning the cartridge group on compr...

Page 66: ...ll as for cleaning the turbine are described in the following Fig 16 Soaking contamination of the turbine Product A mm B mm C mm TPS44 115 20 155 TPS48 115 29 180 TPS52 135 35 215 Table 12 Dimensions...

Page 67: ...rger and damage parts inside the cartridge group u Place the cartridge group on suitable supports 01 made of wood or metal u Observe dimension B for the supports 01 so that the cartridge group is not...

Page 68: ...amination deposits lead to rotor unbal ance This can result in bearing or turbocharger damage u Remove all traces of contamination from the turbine u After brushing off the dirt fill the container 02...

Page 69: ...Turbocharging Service Sta tion Turbine or compressor damaged Bearing damaged Engine Vibrations from engine Contact enginebuilder Table 14 Malfunctions when starting Vibrations Rotating parts rubbing N...

Page 70: ...ing oil pressure too low Speed reduces Possible causes Remedy Turbocharger Turbine and or nozzle ring severely con taminated Clean see chapter Periodic maintenance work 30 Rotor components or bearing...

Page 71: ...ing water too high Check clean cooling system Insufficient ventilation Improve ventilation Table 19 Malfunctions during operation Exhaust gas temperature too high Charge air pressure too low Engine pe...

Page 72: ...A severely contaminated or corroded compressor wheel can reduce the com pressor wheel s fatigue endurance limit and result in the turbocharger being damaged u Rectify malfunction in accordance with t...

Page 73: ...cause clarified and remedied immediately by an ABB Turbochar ging Service Station u Have parts assessed for damage and if necessary replaced by an ABB Turbocharging Service Station Possible causes Rem...

Page 74: ...ble 25 Malfunctions when stopping Runout noises Runout time too short The runout time must be noted down as a reference Because the runout time depends on the oil viscosity the runout time must always...

Page 75: ...r to chapter Ordering spare parts 75 Replacing the speed sensor 22 Table 27 Malfunction of the speed measurement system No signal or poor signal amplitude Measured speed too high Possible causes Remed...

Page 76: ...u Wait for the turbocharger to cool down before carrying out any work Wear safety gloves to protect against thermal hazards WARNING Cutting injuries when working on the turbocharger Some parts on the...

Page 77: ...ult Docu mentKind Catalogue QueryText spare parts set SortBy Score CountryCode CH Addition alLanguage Identification of the assembly devices Not all assembly devices are marked with a part number Iden...

Page 78: ...n the crane hook u People must not stand beneath suspended loads Wear safety gloves to protect against mechanical hazards Wear safety helmet Definition of terms Suspension point Defined loading point...

Page 79: ...ms scope of delivery Swivel lifting eye S to be used Product Thread Length H mm Diameter D mm Minimum load limit kg TPS44 M8 12 25 300 TPS48 M8 12 25 300 TPS52 M10 15 25 400 Table 30 Swivel lifting ey...

Page 80: ...hts of the individual parts or assemblies are rounded up standard values Fig 17 Overview of assemblies Designation TPS44 TPS48 TPS52 01 Radial air suction branch 5 6 8 02 Axial air suction branch 3 4...

Page 81: ...ision E July 2017 9 3 Removing the gas outlet casing u Mark the casing position for assembly Note Gas outlet casings which are not from ABB may also be secured with studs and nuts Fig 18 Removing the...

Page 82: ...2017 9 4 Removing air inlets u Mark the casing position for assembly Fig 19 Removing the air inlets 1 Manually secure the filter silencer 81000 or air suction branch 82000 2 Loosen and remove V clamp...

Page 83: ...ng Copyright 2017 ABB All rights reserved HZTL4037_EN Revision E July 2017 9 5 Removing the compressor casing Fig 20 Removing the compressor casing 1 2 1 Place the turbocharger in a vertical position...

Page 84: ...for assembly Fig 21 Removing the compressor casing 2 2 1 Secure lifting gear to compressor casing 72000 2 Remove the compressor casing 72000 vertically 3 Rotate the compressor casing 72000 through 18...

Page 85: ...he admissible values an oil orifice is mandatory at the oil inlet of the bearing casing if the oil inlet pressure is 3 bar overpressure If an oil orifice is fitted in the oil inlet of the bearing casi...

Page 86: ...ghts reserved HZTL4037_EN Revision E July 2017 Removing the turbine end fastening strips u Mark the casing position for assembly Fig 23 Removing the cartridge group 1 1 Loosen the hexagon nuts 51007 2...

Page 87: ...h washers 3 Secure the lifting gear to the ring nuts and swivel lifting eye as shown 4 Remove the cartridge group vertically from the turbine casing Fig 25 Rotating the cartridge group and fitting the...

Page 88: ...ling and fitting 9 7 Removing nozzle ring Copyright 2017 ABB All rights reserved HZTL4037_EN Revision E July 2017 9 7 Removing nozzle ring Fig 26 Removing the nozzle ring 1 Remove the nozzle ring 5600...

Page 89: ...86 1 52 TPS52 0 13 0 22 0 98 1 68 Table 33 Permissible clearances A and B 1 Move the rotor to and fro up to the stop In order to obtain a correct measurement elev ate the turbine a little 2 Measure c...

Page 90: ...1 and the turbine casing 51000 Fig 28 Measuring nozzle ring compression 42001 Bearing casing 51000 Turbine casing 56001 Nozzle ring 1 Measure dimensions A B and C on cleaned surfaces 2 Calculate the c...

Page 91: ...Revision E July 2017 9 10 Fitting the diffuser Fig 29 Fitting the diffuser Part number TPS44 TPS48 TPS52 72041 M5 5 Nm M5 5 Nm M6 10 Nm Table 35 Tightening torque 72041 1 Position the diffuser 79000 i...

Page 92: ...ing it by 90 1 Fit a new high temperature resisting O ring 42012 red or green see Customer spare part set 97070 47 2 Loosen and remove nuts 3 Lift the cartridge group out of the service support 90012...

Page 93: ...ridge group Fig 31 Fitting the cartridge group Part number TPS44 TPS48 TPS52 72011 M8 40 Nm M8 40 Nm M10 80 Nm Table 36 Tightening torque 72011 1 Lower cartridge group carefully into the compressor ca...

Page 94: ...2017 9 12 Installing nozzle ring Fig 32 Installing the nozzle ring 1 Fit lamellar sealing ring 56005 in the slot of the nozzle ring When doing this pay atten tion to correct winding of the lamellar s...

Page 95: ...PS52 51007 M8 30 Nm M8 30 Nm M10 60 Nm Table 37 Tightening torque 51007 1 Coat the threads of the studs 51006 with high temperature grease 2 Turn the turbine casing 51000 by 180 3 Fit two swivel lifti...

Page 96: ...7_EN Revision E July 2017 9 14 Rotating the turbocharger Rotating the turbocharger Fig 34 Rotating the turbocharger 1 Fit swivel lifting eye S 2 Insert screws from the service support 3 Fit ring nuts...

Page 97: ...ce The upper direc tion N1 and lower direction N2 must be covered simultaneously 2 Calculate clearance N and compare it with the permissible values in the table 3 Push the feeler gauges 01 into the ga...

Page 98: ...Nm M10 50 Nm Table 39 Tightening torque 51101 1 Coat the threads of the hexagon head screws or studs 51008 with high temperature grease 2 Align the casing position of the gas outlet casing 61001 to th...

Page 99: ...44 TPS48 TPS52 72020 M10 30 Nm M10 30 Nm M10 30 Nm Table 40 Tightening torque 72020 1 Fit the new O ring 81010 82010 to the filter silencer 81000 or the air suction branch 82000 2 Manually position th...

Page 100: ...50 Nm 03 72020 M10 30 Nm M10 30 Nm M10 30 Nm 04 72041 M5 5 Nm M5 5 Nm M6 10 Nm 05 72011 M8 40 Nm M8 40 Nm M10 80 Nm 06 42188 M12 x 1 5 35 Nm M12 x 1 5 35 Nm M12 x 1 5 35 Nm 07 51007 M8 30 Nm M8 30 Nm...

Page 101: ...hazards CAUTION Directives for taking out of operation Serious damage to engine or property can be caused by non compliance with the directives for blanking the turbocharger off the engine u Follow t...

Page 102: ...ected against corrosion Preparations for mothballing WARNING Handling operating materials and supplies Swallowing or inhaling vapours of operating materials and supplies or con tact with them may be h...

Page 103: ...the rotor and bearing parts are dismantled by an ABB Turbocharging Service Station and stored separately The turbocharger is completely removed either as a whole unit or in individual parts For the m...

Page 104: ...es Wear a respiratory mask to protect against dusts Wear safety gloves to protect against mechanical hazards Disposal must be environmentally compatible professional and in compliance with locally app...

Page 105: ...harger must be kept intact and ready for use u Carefully clean any rusted parts and grease them Please quote the following data when making queries and ordering spare parts Turbocharger type Serial nu...

Page 106: ...e casing mechanically 34 Fig 16 Soaking contamination of the turbine 36 Fig 17 Overview of assemblies 50 Fig 18 Removing the gas outlet casing 51 Fig 19 Removing the air inlets 52 Fig 20 Removing the...

Page 107: ...40 Table 19 Malfunctions during operation Exhaust gas temperature too high 41 Table 20 Malfunctions during operation Charge air pressure too low 41 Table 21 Malfunctions during operation Charge air p...

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