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Operation Manual / TPL65VA32 / VA33

1 Preliminary remarks / 1.5 Essential information

HZTL2464_EN

Rev.E

March 2020

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 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 trademarks

Registered trademarks of external companies are used in this document.
The trademarks are marked with ®.

Page

108

Summary of Contents for HT604575

Page 1: ...ABB Turbocharging Type TPL65VA32 HT604575 nMmax 499 t Mmax 680 nBmax 475 t Bmax 650 1 s C 01210 35 50 50 Year 2021 Application according to the Operation Manual kg HZTL2464 English TPL65VA32 Original...

Page 2: ...eplacement 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...

Page 3: ...s 17 2 5 Warning plates on the turbocharger 18 2 6 Safe operation and maintenance 18 2 7 Hazards during operation and maintenance 21 2 8 Periodic checking of the pressure vessel 27 2 9 Lifting loads 2...

Page 4: ...4 Axial clearance 79 8 5 Removing cartridge group 79 8 6 Removing and fitting turbine diffuser 84 8 7 Removing variable turbine geometry module with gas inlet casing 85 8 8 Fitting the variable turbi...

Page 5: ...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...

Page 6: ...reserved HZTL2464_EN Rev E March 2020 1 2 Layout and function 01Filter silencer 08Nozzle ring 02Radial plain bearing 09Turbine wheel 03Thrust bearing 10Bearing casing 04Bearing bush 11Diffuser 05Radia...

Page 7: ...es through the diffuser 11 and leaves the turbocharger through the air outlet cas ing 13 The rotor runs in two radial plain bearings 02 05 One plain bearing is in the bearing bush 04 and the second on...

Page 8: ...iminary remarks 1 2 Layout and function Copyright 2020 All rights reserved HZTL2464_EN Rev E March 2020 Additional function TPL V These turbocharger types have adjustable guide vanes at the turbine en...

Page 9: ...er 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...

Page 10: ...otection 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 Ensu...

Page 11: ...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...

Page 12: ...f 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 Opera...

Page 13: ...arts 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 u Only use original parts from ABB...

Page 14: ...t 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 turbochargi...

Page 15: ...ilitate 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 pl...

Page 16: ...ed with the enginebuilder 02 Turbocharger operating limits during operation Recommended replace ment intervals for tur bocharger components 03 Replacement interval for plain bearings in 1000 h 04 Repl...

Page 17: ...mally 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 t...

Page 18: ...f insufficient observance of the safety instruc tions are the consequence of unsatisfactory and improper execution of maintenance and inspection work The operating company is responsible for access to...

Page 19: ...otection 2 4 Definition of Safety instructions The following symbols and terms used in this manual concern safety or refer to possible hazards WARNING Definition of warning Serious personal injuries a...

Page 20: ...maintenance The instructions specified in this section are for the safety of personnel Together with the instructions in the Hazards during operation and maintenance section they allow the user to sa...

Page 21: ...protective equipment PPE for welding operations Safety during start up commissioning and operation u Before starting work carry out visual inspection of working area u Remove any obstacles and objects...

Page 22: ...reserved HZTL2464_EN Rev E March 2020 u Observe the material safety data sheet for the cleaning agent or solvent u Wear personal protective equipment PPE according to the material safety data sheet u...

Page 23: ...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 t...

Page 24: ...ional 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 instr...

Page 25: ...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...

Page 26: ...er 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...

Page 27: ...nation of the ground and water due to improper disposal can lead to environmental damage u Handle operating and auxiliary materials carefully u Heed the instructions for use safety data sheets and haz...

Page 28: ...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...

Page 29: ...ust be observed The operating company is responsible for the safe operation of the pressure vessel WARNING Danger due to pressure vessels The operating company must make sure the pressure vessels are...

Page 30: ...ding u Fasten turbocharger assemblies components as described in re spective handling steps u Before attaching slings allow turbocharger components to cool down maximum 80 C u Use suitable protection...

Page 31: ...an important prerequisite for trouble free turbocharger operation The turbocharger is normally lubricated with oil from the engine oil cir cuit NOTICE With regard to the oil supply please observe the...

Page 32: ...charger 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...

Page 33: ...ng 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 tempe...

Page 34: ...hat the entire lubricating system be flushed thoroughly with warm oil using a bypass pipe before starting up the first time commissioning and after all service work on the lub ricating system It is ur...

Page 35: ...of the variable turbine geometry module 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...

Page 36: ...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 ope...

Page 37: ...arger The highest sound pressure level of emissions1 reaches a maximum of 105 dB A near the filter silencer and over the entire speed range The following prerequisites must be fulfilled on the turboch...

Page 38: ...ges 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 tha...

Page 39: ...ve unknown causes clarified by an ABB Turbocharging service sta tion 4 2 2 Entries in engine logbook By monitoring the engine conclusions can be drawn about the tur bocharger performance The following...

Page 40: ...try module overhauled by ABB Tur bocharging ABB Turbocharging Service Stations have variable turbine geometry modules replaced with overhauled ones as part of the CPEX Customer Part Exchange programme...

Page 41: ...nspections are carried out the individual components are inspected for wear and tear and replaced if necessary In this way trouble free operation is ensured Influencing parameters The following parame...

Page 42: ...variable turbine geometry module can be re placed with a CPEX variable turbine geometry mod ule by an ABB Turbocharging service station 15000 Turbine diffuser cover ring 35000 50000 Other casings 100...

Page 43: ...March 2020 CAUTION Do not use cables as a climbing aid If you pull the speed measurement cables too hard contacts can be pulled out u Do not tension the speed measurement cables Part number Descriptio...

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...

Page 45: ...t w Engine and turbocharger are not running w The turbocharger lubricating system is switched off u Remove screw plug 42047 from bearing casing NOTICE Part position The position of the screw plug for...

Page 46: ...tch 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 block u O...

Page 47: ...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 engineb...

Page 49: ...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 b...

Page 50: ...v E March 2020 5 2 Cleaning the filter silencer 5 2 1 Filter silencer and connecting rod 81265 Filter ring if provided 81136 Absorption segment 81269 Connecting rods 81137 Sheet metal covering 81266 C...

Page 51: ...is Clean filter strip every 500 hours of service or more frequently if necessary u Unscrew and remove lock nuts 81273 u Unscrew and remove screws 81272 for connecting rods 81269 u Remove connecting r...

Page 52: ...etal coverings 81137 back to original shape u Insert the insert units E into slot guides in filter silencer unit 81135 u Install cover grids 81266 uniformly and in the correct position u Push connecti...

Page 53: ...e enginebuilder approves the process General The contamination of the compressor stage compressor wheel wall in sert and diffuser depends on the degree of purity of the air that is drawn in Deposits c...

Page 54: ...injection pipe fitted in the fil ter silencer or the suction branch The water does not act as a solvent but the contamination deposit is re moved by the mechanical impact of the droplets This is a ve...

Page 55: ...e present in the vicinity of the tur bocharger during compressor cleaning u Compressor cleaning must be activated from the engine control panel Wet cleaning procedure for compressor with XC2 u Trigger...

Page 56: ...n tested and is recommended by ABB Turbocharging the following pre requisites must be fulfilled u Engine load 50 85 u Start of cleaning cycle in accordance with following description for wet cleaning...

Page 57: ...ameters per turbocharger compressor Product Engine load Contents of water ves sel dm3 TPL65 50 85 0 4 5 4 Cleaning turbines and guide vanes during operation NOTICE HFO applications The TPL65VA has not...

Page 58: ...chapter Fitting and dismantling u Dispose of contaminated water and cleaning agents in an environ mentally compatible manner professionally and in accordance with valid local regulations CAUTION Risk...

Page 59: ...ot use any wire brushes u Dry the compressor wheel and the gap between the compressor and the bearing casing with a weak jet of compressed air u Lightly spray the gap between the compressor and the be...

Page 60: ...fting gear length 1 Suspend cartridge group from normal suspension point and suspend from first crane 2 Secure two lifting loops with swivel lifting eyes in the lower push off threads and suspend from...

Page 61: ...Operation Manual TPL65VA32 VA33 5 Maintenance 5 5 Cleaning components mechanically Copyright 2020 All rights reserved HZTL2464_EN Rev E March 2020 6 Remove loop from first crane Page 59 108...

Page 62: ...must not touch the compressor wheel at any time dur ing rotation u Choose appropriate lifting gear length 1 Suspend cartridge group from the two side suspension points on the crane using two lifting...

Page 63: ...il entire cartridge group is suspended from first crane 6 Remove loop from second crane CAUTION Selection of the cleaning agent Cleaning agents that contain chlorine corrode metals u Only use pH neutr...

Page 64: ...If water or contamination gets into the cartridge group the turbochar ger function may be impaired and parts in the cartridge group may be damaged u Place cartridge group on suitable wooden or metal s...

Page 65: ...ation deposits lead to rotor unbalance This can result in bearing or turbocharger damage u Remove all traces of contamination from the turbine u After brushing off the contamination fill the tank with...

Page 66: ...viour 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 b...

Page 67: ...arified 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...

Page 68: ...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 engine...

Page 69: ...on 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...

Page 70: ...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...

Page 71: ...for the evaluation electronics This problem is eliminated by removing the gasket Defective sensor Contact ABB Turbocharging service sta tion Measured speeds too high Dirty sensor tip The sensor tip is...

Page 72: ...leshooting 6 6 Variable Turbine Geometry Copyright 2020 All rights reserved HZTL2464_EN Rev E March 2020 Possible causes Elimination Drive unit electrical com ponents No drive energy Contact an ABB Tu...

Page 73: ...r and oil lines in accordance with engine manu facturer s instructions CAUTION Oil orifices There is an orifice for adjusting the oil pressure in each of the two oil supply pipes of the bearing casing...

Page 74: ...Fasten separate lifting gear to each of the two ribs on the bearing casing provided for this purpose w Ribs 01 not in the middle at the top u Completely remove the bearing casing insulation 02 and pla...

Page 75: ...casing ribs provided for this purpose CAUTION Oil orifices There is an orifice for adjusting the oil pressure in each of the two oil supply pipes of the bearing casing When the cartridge group the be...

Page 76: ...on the cartridge group can lead to total system failure and void the warranty u Mark the casing position for assembly Identifying assembly devices Not all assembly devices are marked with a part numb...

Page 77: ...chnically perfect condition 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 prote...

Page 78: ...Rev E March 2020 Weights kg 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...

Page 79: ...plete compressor casing Weight kg 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 8 3...

Page 80: ...stall filter silencer in reverse order Removing the air suction branch u Disconnect all air lines in accordance with the engine builder s instruc tions u Dismantle the insulation where necessary u Pas...

Page 81: ...be measured before removing and after fitting the cartridge group u Measure and note the axial clearance A Clearance A mm TPL65VA32 33 0 31 0 49 CAUTION Clearances out of tolerance Clearances out of t...

Page 82: ...ng fitted to the engine it must be ensured that the orifices specified for the turbocharger are installed in both oil supply pipes u Check that the oil orifices have been correctly installed u Loosen...

Page 83: ...and diffuser and set them down with surface F on an underlay WARNING Tipping the compressor casing Make sure the underlay does not shift u Allow the compressor casing to rest only on surface F u Check...

Page 84: ...emove the three screws 61059 together with their Verbus Ripp washers 61058 u Attach one lifting gear each to the two fins of the bearing casing provided for this purpose u Evenly press off cartridge g...

Page 85: ...rtridge group Copyright 2020 All rights reserved HZTL2464_EN Rev E March 2020 u Withdraw cartridge group and fit supports 90450 u Remove screws 42054 together with flange 42044 and also remove possibl...

Page 86: ...er u Replace two screws 61032 with two studs 90903 in upper section of turbine diffuser u Screw out the remaining screws 61032 press off the turbine diffuser 63000 using the press off screws 90901 the...

Page 87: ...together with variable turbine geo metry module 56100 CAUTION After removing screws 56122 and retaining clips 56121 gas inlet cas ing 51001 is no longer secured u Loosen screws 56122 together with re...

Page 88: ...8 8 Fitting the variable turbine geometry module and the gas inlet casing u Push variable turbine geometry module 56100 over studs u Push gas inlet casing 56001 over studs u Slide clamping ring 56112...

Page 89: ...alling cartridge group CAUTION Oil orifices There is an orifice for adjusting the oil pressure in each of the two oil supply pipes of the bearing casing When the cartridge group the bear ing casing or...

Page 90: ...u Remove supports 90450 and carefully insert cartridge group u Uniformly tighten the screws 61059 together with the Verbus Ripp washers 61058 CAUTION If there is no or insufficient clearance between...

Page 91: ...Rev E March 2020 u Fit the O ring 77005 to the wall insert 77000 u Fit the lifting gear and the swivel lifting eye 90235 u Align and fit the wall insert 77000 using the centring screw 90187 u Place th...

Page 92: ...onto bearing casing studs equally spaced around circumference and up to end of thread u Push compressor casing 72000 onto cartridge group to fit snugly and fasten it using nuts 61037 u Secure three p...

Page 93: ...e and excessively worn components can be the cause of serious damage to machinery and property u Have components assessed and if necessary replaced by an ABB Turbocharging Service Station u Connect oi...

Page 95: ...Operation Manual TPL65VA32 VA33 8 Disassembly and assembly 8 10 Table of tightening torques Copyright 2020 All rights reserved HZTL2464_EN Rev E March 2020 8 10 Table of tightening torques Page 93 108...

Page 96: ...rques Nm 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...

Page 97: ...Machine damage in emergency operation The assembly of the locking device on the turbocharger is only permiss ible in emergencies It is not permitted to lock the rotor for an engine test Serious damage...

Page 98: ...20 9 2 Fit cover plate NOTICE The cover plate material General structural steel in accordance with DIN EN 10025 2 must be manufactured in house according to the drawing Cover plate dimensions mm Produ...

Page 99: ...Taking out of operation at short notice 9 2 Fit cover plate Copyright 2020 All rights reserved HZTL2464_EN Rev E March 2020 NOTICE Carry out the work as described in the chapter Removal and fitting u...

Page 100: ...2 Fit cover plate Copyright 2020 All rights reserved HZTL2464_EN Rev E March 2020 u Close off opening in gas outlet casing using cover plate u Fasten cover plate using spacer sleeves and nuts 61037 CA...

Page 101: ...builder s instructions Common receiver The air line must be closed off at the engine end because the undam aged turbochargers build up a receiver pressure CAUTION The engine can be operated according...

Page 102: ...2 VA33 9 Taking out of operation at short notice 9 4 Bypass the turbochar ger Copyright 2020 All rights reserved HZTL2464_EN Rev E March 2020 NOTICE In this respect refer to the engine manufacturer s...

Page 103: ...d 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...

Page 104: ...an 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...

Page 105: ...for more than 12 months Copyright 2020 All rights reserved HZTL2464_EN Rev E March 2020 Condition of the mothballed turbocharger u Check the mothballed turbocharger parts for corrosion once per an num...

Page 106: ...ask 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 Th...

Page 107: ...ideration 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 u Pa...

Page 109: ...ion Manual TPL65VA32 VA33 12 Spare parts 12 2 View of turbocharger with part numbers Copyright 2020 All rights reserved HZTL2464_EN Rev E March 2020 12 2 View of turbocharger with part numbers Page 10...

Page 110: ...ustomer 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 Washe...

Page 111: ...ABB Switzerland Ltd Turbocharging Bruggerstrasse 71a CH 5401 Baden Switzerland...

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