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Turbocharging

Operation Manual / TPS44-H31

HT607822

Document identification

Document number

HZTL4037

Revision

G

Language

English

Original Operation Manual

Product identification

Serial number

HT607822

Customer part number

1004181963

Delivery date (yyyy-mm-dd)

2022-01-25

Weight

120

kg

Operating limits according to rating plate

Speed limit in test rig operation only

n

Mmax

1232

1/s

Speed limit during operation

n

Bmax

1176

1/s

Gas inlet temperature limit in test rig operation only

t

Mmax

680

°C

Gas inlet temperature limit during operation

t

Bmax

650

°C

Summary of Contents for HT607822

Page 1: ...on Serial number HT607822 Customer part number 1004181963 Delivery date yyyy mm dd 2022 01 25 Weight 120 kg Operating limits according to rating plate Speed limit in test rig operation only nMmax 1232...

Page 2: ......

Page 3: ...14 2 6 Deflagration on gas engines 15 2 7 Warning plates on the turbocharger 16 2 8 Turbocharger rating plate 17 2 9 Lifting of loads 19 2 10 Prerequisites for operation and maintenance 20 2 11 Hazar...

Page 4: ...g the compressor casing 76 10 7 Removing the cartridge group 77 10 8 Removing nozzle ring 80 10 9 Measuring clearance A and B 81 10 10 Nozzle ring compression PD 82 10 11 Fitting the diffuser 83 10 12...

Page 5: ...f contents Copyright 2021 ABB All rights reserved HZTL4037_EN Rev G June 2021 14 Spare parts 98 14 1 Ordering spare parts 98 14 2 Required customer spare part set 97070 98 14 3 Spare part Illustration...

Page 6: ...plains 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 7: ...is document is valid for different design variants of turbochargers There may be sections and descriptions of components that are not relevant for a specific turbocharger variant Please contact an ABB...

Page 8: ...EN Rev G June 2021 1 5 Layout and function of the turbocharger Fig 2 Layout and function of the turbocharger 01 Air suction branch filter silencer 07 Plain bearing bush 02 Compressor casing 08 Turbine...

Page 9: ...air and gas through the air suction branch 01 or the filter silencer In the compressor wheel 11 the energy required for build ing up the pressure is transferred to the air By flowing through the diff...

Page 10: ...ndatory signs are described in chapter Safety and must be complied with Definition of Caution Warning Caution and warning signs are described in chapter Safety ABB Turbocharging ABB Switzerland Ltd Tu...

Page 11: ...togram 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 othe...

Page 12: ...RNING Health protection when handling VCI VCI products are not hazardous in terms of the Ordinance on Hazardous Substances Nevertheless the following points must be observed when handling VCI u Observ...

Page 13: ...nspected 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 Turbocharging Service Station and...

Page 14: ...are a consequence of insufficient compliance with safety instructions are a consequence of insufficient or inappropriate performance of maintenance and in spection work The operating company is respo...

Page 15: ...ory mask to protect against Dusts Gases Safety helmet Ear protection Table 3 Personal protective equipment to be worn specific to the respective task 2 4 Definition of safety instructions WARNING Defi...

Page 16: ...ded to be operated with a clockwise direction of rotation as viewed from the turbine end The specific operating limits of the turbocharger were determined on the basis of informa tion from the engineb...

Page 17: ...tur bocharger or improper operation 2 6 Deflagration on gas engines ABB turbochargers can tolerate a deflagration with a transient pressure increase of 12 bar After a deflagration event ABB recommends...

Page 18: ...present in the designated locations or not readable proceed as fol lows u Order new warning plates from ABB Turbocharging Service Stations u Remove any warning plates that have become unreadable u Cle...

Page 19: ...nterval of turbine in 1000 h If the turbocharger is used for the Peak shaving mode with frequent engine start stop cycles the number of successful engine start stop cycles must be taken into account i...

Page 20: ...ecommend contacting the nearest ABB Turbochar ging Service Station nMmax tMmax normally apply only when running at overload 110 during trials on the engine test bed These limit values can also be perm...

Page 21: ...mechanical hazards Wear safety helmet Fig 8 Attachment of loads on the crane hook Fig 9 Attachment angle If there are two or more suspension points the attachment angle of 45 must not be ex ceeded Th...

Page 22: ...ation Manual must be checked 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 t...

Page 23: ...ear 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 and operating fl...

Page 24: ...viding protection against contact with hot surfaces u Compliance with the instructions and specifications given by the en ginebuilder to protect against hot turbocharger surfaces is compulsory Wear sa...

Page 25: ...d objects littering the workplace u Check all pipes to and from the turbocharger for damage and leaks before commission ing u Check turbocharger for recognisable damage or defects every 12 hours of op...

Page 26: ...operations for which you have 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 wor...

Page 27: ...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 Inspect the electric cables for abrasio...

Page 28: ...ns for which you have 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...

Page 29: ...he 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 Dus...

Page 30: ...aviest variant possible Depending on the specification the weight specified on the rating plate may be lower than the standard value specified here Produkt Gewicht Turbolader komplett kg TPS44 120 TPS...

Page 31: ...Wear safety gloves to protect against thermal hazards CAUTION Do not put the speed measurement cables under strain by pulling them If you pull the speed measurement cables too hard contacts can be pu...

Page 32: ...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 turbocharger con nection may be in the form of a pin with the...

Page 33: ...sealing is provided by O rings The O rings are not included in the ABB scope of delivery Fig 12 Inserting gaskets into the bracket 01 Bracket 04 Slot for O ring 02 Oil supply 05 O rings 03 Oil drain 0...

Page 34: ...Remove nuts 01 again Requirements for the threaded rods 02 Fig 14 Requirements for threaded rods Product Diameter Threaded rod mm Material DIN ISO 898 Part 1 Thread length L1 mm Length of threaded ro...

Page 35: ...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 turbocharger over the threaded rods of the bracket 5...

Page 36: ...ations regarding the selection of lubricating oil and the oil change intervals 4 1 2 Pre lubrication Pre lubrication must be carried out as follows u Switch on the oil pump u Build up oil pressure u D...

Page 37: ...ystem 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 service work flus...

Page 38: ...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 the enginebuilder s instruc tions Wear safety glov...

Page 39: ...king 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 foreign...

Page 40: ...operation Pressure at oil inlet upstream of the turbocharger bar Overpressure Normal operation 2 0 poil 4 5 Engine start Cold oil admissible for a maximum of 15 minutes 8 0 Engine idling admissible f...

Page 41: ...ht 2021 ABB All rights reserved HZTL4037_EN Rev G June 2021 If the drain pipe is vented the lubricating oil temperature measuring point can be installed at the outlet in the vent tank Otherwise the me...

Page 42: ...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 adm...

Page 43: ...troduction A speed measuring system enables the constant monitoring of the turbocharger speed CAUTION Do not put the speed measurement cables under strain by pulling them If you pull the speed measure...

Page 44: ...N Rev G June 2021 5 3 2 Layout and overview Fig 16 Layout and overview of the speed measurement system 86505 Speed sensor 42188 Screw plug 86515 Cable connector 42189 Gasket 86526 F I converter 01 Plu...

Page 45: ...t 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 temperatures in the a...

Page 46: ...ng No additional gasket is required during assembly Fig 17 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 11 Tightening torque 86505...

Page 47: ...f 1 meter from the turbocharger The highest value of the emission sound pressure level1 reaches a maximum of 105 dB A near the air inlet The following prerequisites must be fulfilled with regard to th...

Page 48: ...021 ABB All rights reserved HZTL4037_EN Rev G June 2021 Suggestion for noise insulation bellows Fig 18 Noise insulation bellows 01 Compressor casing 02 Bellows 03 Charge air duct scavenging air duct 0...

Page 49: ...d or performed too late can cause excessive contamination wear and operating failures u Carry out the service work at the specified time intervals CAUTION Specific service interval Exceptional stresse...

Page 50: ...f the enginebuilder Performance and speed of the engine Air intake temperature Charging pressure Pressure loss in the charge air cooler Lubricating oil pressure and lubricating oil temperature If pres...

Page 51: ...y fast and are very sens itive to unbalance The rotor and bearing parts must be checked and assessed by an ABB Turbocharging Service Station The following work can be carried out as preparation u Remo...

Page 52: ...e start stop cycles or after reaching the number of operating hours specified on the rating plate Non rotating components Depending on the system specific operating conditions a differentiation must b...

Page 53: ...ne wheels are spe cified 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 n...

Page 54: ...rming 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 Turbocharging C...

Page 55: ...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 cleaning CAUTION...

Page 56: ...fter the fifth cleaning process at the latest Contamination of the filter ring depends on the degree of purity of the sucked in air u Rinse the filter ring 81265 with water and mild detergent or in th...

Page 57: ...aminated absorption segments replaced by an ABB Turbocharging Service Station Fitting the filter silencer see Fig 19 Cleaning the filter silencer 54 u Insert the absorption segments 81136 into the she...

Page 58: ...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 followin...

Page 59: ...al 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 heavy fuel oil...

Page 60: ...cartridge group see chapter Dismantling and fitting 70 First clean the compressor end and then the turbine end according to the following descrip tion 8 2 6 Cleaning the cartridge group on compressor...

Page 61: ...ge group on turbine end Soaking the contamination Baked layers of contamination from fuel residue or coked oil may occur at the turbine end The contamination can be removed by soaking and brushing The...

Page 62: ...C WARNING Heating up of cleaning agents and operating fluids When cleaning agents or operating fluids are heated up explosive vapours can be produced which are hazardous to health u Observe the infor...

Page 63: ...and contamination in the cartridge group If water or contamination penetrates the cartridge group this can impair the function of the turbocharger and damage parts inside the cartridge group u Make s...

Page 64: ...right 2021 ABB All rights reserved HZTL4037_EN Rev G June 2021 u Lightly spray the turbine and the gap between the turbine and the heat sheet metal with penetrating oil u Dispose of contaminated water...

Page 65: ...Service Station Turbine or compressor damaged Bearing damaged Engine Vibrations from engine Contact enginebuilder Table 16 Malfunctions when starting Vibrations Rotating parts rubbing Normal behaviou...

Page 66: ...il filter heavily contaminated Clean Oil pump in lubricating system defect ive Check replace Manometer displays incorrectly Replace manometer Table 18 Malfunctions during operation Lubricating oil pre...

Page 67: ...high Check clean cooling system Insufficient ventilation Improve ventilation Table 21 Malfunctions during operation Exhaust gas temperature too high Charge air pressure too low Engine performance and...

Page 68: ...aminated 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 the following tab...

Page 69: ...d 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 Remedy Turbocharger F...

Page 70: ...tions 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 be measured a...

Page 71: ...ging Service Station Replacing the speed sensor 44 Table 29 Malfunction of the speed measurement system No signal or poor signal amplitude Measured speed too high Possible causes Remedy Turbochar ger...

Page 72: ...ing 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...

Page 73: ...is enclosed with the tool set WARNING Servicing the tools The tools must be checked for damage before and after use u Visually inspect for corrosion cracks deformation and wear u Damaged tools must no...

Page 74: ...tention to the correct attachment of loads on the crane hook u People must not stand beneath suspended loads Wear safety gloves to protect against mechanical hazards Wear safety helmet Definition of t...

Page 75: ...ndividual parts or assemblies are rounded up standard values Fig 25 Overview of assemblies Designation TPS44 TPS48 TPS52 01 Radial air suction branch 5 6 8 02 Axial air suction branch 3 4 4 03 Filter...

Page 76: ...2021 ABB All rights reserved HZTL4037_EN Rev G June 2021 10 4 Removing the gas outlet casing u Mark the casing position for assembly Fig 26 Removing the gas outlet casing 1 Manually secure the gas ou...

Page 77: ...moving air inlets u Mark the casing position for assembly Fig 27 Removing air inlets 1 Manually secure the filter silencer 81000 or air suction branch 82000 2 Loosen and remove V clamp 72020 3 Remove...

Page 78: ...soft underlay 2 Loosen the hexagon head screws 72011 and remove them with fastening strips 72012 Fig 29 Removing the compressor casing 2 2 1 Secure lifting gear to compressor casing 72000 2 Remove the...

Page 79: ...t 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 casing it must not be removed Do not loosen screw plug...

Page 80: ...Ripp washers 51003 and fastening strips 51002 3 Screw in the swivel lifting eye S up to the stop Removing the cartridge group Fig 33 Removing cartridge group 2 1 Insert screws from service support in...

Page 81: ...e cartridge group and fitting the service support 1 Lift the cartridge group and rotate in the horizontal position 2 Remove the lifting gear from the ring nuts 3 Remove the ring nuts VRM and screws fr...

Page 82: ...itting 10 8 Removing nozzle ring Copyright 2021 ABB All rights reserved HZTL4037_EN Rev G June 2021 10 8 Removing nozzle ring Fig 35 Removing the nozzle ring 1 Remove the nozzle ring 56001 vertically...

Page 83: ...0 98 1 68 Table 35 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 clearance A and compare it...

Page 84: ...the turbine casing 51000 Fig 37 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 compres...

Page 85: ...10 11 Fitting the diffuser Fig 38 Fitting the diffuser Product Size Tightening torque Nm TPS44 M5 5 Nm TPS48 M5 5 Nm TPS52 M6 10 Nm Table 37 Tightening torque 72041 1 Position the diffuser 79000 in th...

Page 86: ...1 Fit a new high temperature resisting O ring 42012 red or green see Customer spare part set 97070 98 2 Loosen and remove nuts 3 Lift the cartridge group out of the service support 90012 4 Insert the...

Page 87: ...Fitting the cartridge group Product Size Tightening torque Nm TPS44 M8 40 Nm TPS48 M8 40 Nm TPS52 M10 80 Nm Table 38 Tightening torque 72011 1 Lower cartridge group carefully into the compressor casin...

Page 88: ...nstalling the nozzle ring Fig 41 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 sealing r...

Page 89: ...Nm TPS52 M10 60 Nm Table 39 Tightening torque 51007 1 Coat thread of studs 51006 with high temperature grease 2 Fit two swivel lifting eyes 01 on the turbine casing 51000 Secure lifting gear to the s...

Page 90: ...ZTL4037_EN Rev G June 2021 10 15 Turning the turbocharger Fig 43 Rotating the turbocharger 1 Fit swivel lifting eye S 2 Insert screws from the service support 3 Fit ring nuts VRM 4 Attach lifting gear...

Page 91: ...p without clearance and measure simultaneously at the top N1 and the bottom N2 2 Calculate clearance N and compare it with the permissible values in the table 3 Push the feeler gauges 01 into the gap...

Page 92: ...ng Product Size Tightening torque Nm TPS44 M8 25 Nm TPS48 M8 25 Nm TPS52 M10 50 Nm Table 41 Tightening torque 51008 1 Coat thread of studs 51008 with high temperature grease 2 Align the casing positio...

Page 93: ...PS44 M10 30 Nm TPS48 M10 30 Nm TPS52 M10 30 Nm Table 42 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 the fi...

Page 94: ...020 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 M10 60 Nm 0...

Page 95: ...ainst thermal 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 engi...

Page 96: ...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 harmful to heal...

Page 97: ...r 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 measures a...

Page 98: ...the presence of such substance s with sufficient information available to the supplier RoHS2 Directive 2011 65 EC in English only The EU Directive 2011 65 EC recast restricts the use of certain hazar...

Page 99: ...r 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 applicabl...

Page 100: ...vice Station u If different model variants are not taken into account in this document contact an ABB Turbocharging Service Station u Dispose of placed and unusable parts in an environmentally friendl...

Page 101: ...n English Cartridge 42196 42188 p 42189 p 42183 p 98105 10900 42183 p 42182 p 98100 42184 p 42012 Available within the spare part set HZTL443461 Mod A p pre assembled Part no Designation 10900 Cartrid...

Page 102: ...002 51003 51007 Available within the spare part set HZTL443413 Mod B p pre assembled if provided Part no Designation 51000 Turbine casing 51002 Fastening strip 51003 Verbusripp washer 51006 Stud 51007...

Page 103: ...2011 72041 79000 72005 p 72006 p 72000 72080 72020 Available within the spare part set HZTL443414 Mod B p pre assembled Part no Designation 72000 Compressor casing 72005 p Screw plug 72006 p Gasket 72...

Page 104: ...170 p 81266 81271 81270 Available within the spare part set HZTL443011 Mod F p pre assembled if provided Part no Designation 81000 Filter silencer complete 81005 p Screw plugt 81006 p Gasket 81010 O r...

Page 105: ...June 2021 Air suction branch radial 82010 82005 p 82006 p 82000 82008 p 82007 p Available within the spare part set HZTL443416 Mod A p pre assembled Part no Designation 82000 Air sucton branch 82005...

Page 106: ...G June 2021 Air suction branch axial 82005 p 82007 p 82008 p 82006 p 82010 82000 Available within the spare part set HZTL443418 Mod A p pre assembled Part no Designation 82000 Air suction branch 82005...

Page 107: ...t Illustrations Copyright 2021 ABB All rights reserved HZTL4037_EN Rev G June 2021 Gas outlet casing 61005 p 61001 HZTL443417 Mod B p pre assembled Part no Designation 61001 Gas outlet casing 61005 p...

Page 108: ...021 ABB All rights reserved HZTL4037_EN Rev G June 2021 Speed measurement system 86526 86528 86505 86515 HZTL443419 Mod if provided Part no Designation 86505 Speed sensor 86515 Cable connector 86526 F...

Page 109: ...is required for the work described in the Operation Manual Part number Designation Quantity 90012 Service support 1 Table 53 TPS H Tool This tool can be ordered from any ABB Turbocharging Service Sta...

Page 110: ...ng diffuser mechanically 56 Fig 21 Cleaning the nozzle ring turbine casing mechanically 57 Fig 22 Soaking contamination of the turbine 59 Fig 23 Swivel lifting eyes 71 Fig 24 Ring nuts 72 Fig 25 Overv...

Page 111: ...e 23 Malfunctions during operation Charge air pressure too high 66 Table 24 Malfunctions during operation Engine performance losses 66 Table 25 Malfunction Turbocharger pumping 67 Table 26 Malfunction...

Page 112: ......

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