ABB HT842293 Operation Manual Download Page 139

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Operation Manual / TPL76-C

Taking out of operation at short notice

Fit cover plate

9.3

Page 137

Febr

uar

y 2016

L2485_

ion

Further measures and information for operation with a turbocharger with

cover plate on 4-stroke engines

4-stroke engine with one turbocharger

No further measures are necessary. The engine can be operated as a

naturally-aspirated engine according to the engine builder's instructions.

4-stroke engine with several turbochargers

No further measures are necessary on engines with separate air and

exhaust gas receivers. The engine can be operated as a naturally-

aspirated engine according to the engine builder's instructions.

The air line must be closed off at the engine end because the undamaged

turbochargers build up a receiver pressure.

CAUTION

The engine can be operated according to the engine builder's

instructions. Attention must always be paid to the speed of the

undamaged turbocharger. The speed limit n

Bmax

given on the rating

plate must not be exceeded.

Separate receivers

Common receiver

Summary of Contents for HT842293

Page 1: ... Systems Ltd CH 5401 Baden Type TPL76 C33 HT842293 nMmax 348 t Mmax 650 nBmax 342 t Bmax 620 1 s C 04070 35 50 50 Year 2016 made in Switzerland Application according to the Operation Manual kg HZTL2485 English TPL76 C33 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: ...r rating plate 1 9 Contact information 2 Safety 2 1 Introduction 2 2 CE conformity 2 3 Definition of mandatory signs 2 4 Definition of Safety instructions 2 5 Warning plates on the turbocharger 2 6 Safe operation and maintenance 2 7 Hazards during operation and maintenance 2 8 Periodic checking of the pressure vessel 2 9 Lifting loads 3 Commissioning 3 1 Oil supply 3 2 Inspection work 3 3 Commissi...

Page 4: ...ement system 7 Removal and installation 7 1 Turbocharger weight 7 2 Remove the turbocharger 7 3 Installing the turbocharger 8 Disassembly and assembly 8 1 Introduction 8 2 Module weights 8 3 Removing and fitting filter silencer or air suction branch 8 4 Axial clearance 8 5 Removing cartridge group 8 6 Dismantling and installing the turbine diffuser and nozzle ring 8 7 Installing cartridge group 8 ...

Page 5: ...ghts reserved February 2016 HZTL2485_EN Revision C 10 1 Taking out of operation for up to 12 months 10 2 Taking out of operation for more than 12 months 11 Disposing of turbocharger components 12 Spare parts 12 1 Ordering spare parts 12 2 View of turbocharger with part numbers ...

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Page 7: ...bo Systems and 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 regulations concerning work safety and accident prevention Target group This Operation Manual is intended for engineers and qualified mechanics who are responsible for operating the eng...

Page 8: ...rved February 2016 HZTL2485_EN Revision C Layout and function 1 2 01 Filter silencer 08 Nozzle ring 02 Radial plain bearing 09 Turbine wheel 03 Thrust bearing 10 Bearing casing 04 Bearing bush 11 Diffuser 05 Radial plain bearing 12 Compressor wheel 06 Gas outlet casing 13 Compressor casing 07 Gas inlet casing 1 2 ...

Page 9: ...his air then passes through the diffuser 11 and leaves the turbocharger through the compressor casing 13 The rotor runs in two radial plain bearings 02 05 One plain bearing is in the bearing bush 04 and the second one is in the axial thrust bearing 03 at the compressor end The plain bearings are connected to a central lubricating oil duct which is fed with oil from the engine s lubricating oil cir...

Page 10: ...he turbine end The specific operating limits of the turbocharger were determined on the basis of information from the enginebuilder about the intended use These data are given on the rating plate ABB Turbo Systems accepts no liability and rejects all warranty claims for any non intended uses 1 Euromot The European Association of Internal Combustion Engine Manufacturers 2 Directive 94 9 EC concerni...

Page 11: ...d modifications to the turbocharger or improper operation Deflagration on gas engines 1 4 ABB turbochargers can tolerate a deflagration with a transient pressure increase of 12 bar ABB Turbo Systems recommends subjecting the turbocharger to a visual inspection after a deflagration event As part of the inspection the position of the turbine casing and the position of the compressor casing to the be...

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

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

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

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

Page 16: ...cy of illustrations The illustrations in this document are general in nature and intended for ease of understanding Differences in detail are therefore possible Storage of new turbochargers New turbochargers supplied by ABB Turbo Systems can be stored without additional safeguarding measures for a period of 6 months after the delivery date Suitable storage locations are dry rooms where the relativ...

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

Page 18: ...se agreed with the enginebuilder 02 Turbocharger operating limits during operation 03 Replacement interval for plain bearings in 1000 h 04 Replacement interval for compressor in 1000 h 05 Replacement interval for turbine in 1000 h 06 Part number for customer 07 Designation of special design 08 Turbocharger weight in kg 09 Turbocharger type 10 Serial number 11 Year of turbocharger construction 1 8 ...

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

Page 20: ...ved February 2016 HZTL2485_EN Revision C Contact information 1 9 Contact information Contact information for the official service stations of ABB Turbo Systems is available online Scan the QR code to access our website ABB Turbo Systems Ltd Bruggerstrasse 71a CH 5401 Baden Switzerland www abb com turbocharging 1 9 ...

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

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

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

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

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

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

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

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

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

Page 30: ...anner in accordance with statutory regulations Hazards when handling insulating materials WARNING Hazards due to insulating materials Dust and fibres from insulating materials can cause damage to health or irritations Unsuitable combustible insulating materials signify a fire hazard Use only suitable non combustible insulating materials Ensure that the work area is well ventilated Avoid stirring u...

Page 31: ...ng old insulating materials Dispose of insulating materials properly and in an environmentally compatible way in accordance with applicable local regulations Hazards due to electrical components WARNING Hazards due to electrical components Electrical components operate with voltages which can present hazards to humans All work on or with electrical components may only be performed by trained speci...

Page 32: ... called simple pressure vessels The local statutory regulations covering periodic checks of pressure vessels must be observed The operator is responsible for the safe operation of the pressure vessel WARNING Hazards from pressure vessels The operator must keep the pressure vessel in a proper condition and monitor it Necessary repair or maintenance work must be carried out without delay and the req...

Page 33: ...tand beneath a suspended load Wear safety gloves against mechanical risks Wear safety helmet In the case of two or more suspension points the slinging angle must not exceed 45 This avoids excessive loading due to inclined tensile loading Fasten turbocharger assemblies components as described in respective handling steps Before attaching slings allow turbocharger components to cool down maximum 80 ...

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Page 35: ...ble free turbocharger operation The turbocharger is normally lubricated with oil from the engine oil circuit NOTICE With regard to the oil supply please observe the engine builder s specifications for lubricating oil selection oil change intervals oil filtration oil pressure and oil temperature Oil filtration A lubrication oil filter system with a mesh size 0 050 mm is adequate for TPL76 C turboch...

Page 36: ...n on the turbocharger are listed below Status for operation Oil pressure in front of the turbocharger bar Permissible for normal operation 1 3 2 5 Permissible during engine warm up 1 3 5 0 Temporarily permissible 1h alarm 1 1 1 3 Not permissible emergency stop 0 0 1 1 Permissible during pre and post lubrication engine stopped 0 2 2 5 NOTICE Oil orifice To make sure these oil pressures are obtained...

Page 37: ...ating oil temperature at outlet The oil temperature at the outlet is mainly dependant on Lubricating oil temperature and pressure at the oil inlet Engine load and turbocharger speed Exhaust gas temperature The maximum admissible oil temperature at the outlet is listed in the following table The specified oil outlet temperature is to be considered as alarm value for the turbocharger operation and m...

Page 38: ...filter for cleanliness before commissioning CAUTION Contaminated oil Particles of dirt and solid matter in the oil can cause serious damage to the machine or property During initial commissioning and after all service work the complete lubricating system must be flushed thoroughly with warm oil When running in the engine and after all service work on the lubricating system special running in filte...

Page 39: ...perature in front of and behind turbine Measure air temperature in front of and behind compressor The measured values must be compared with the values in the acceptance test report while taking different operating conditions into account NOTICE Lubricants and pastes used during assembly of the turbocharger liquefy or vaporise and might escape as an oily liquid in the first few hours after commissi...

Page 40: ...uct before gas inlet and after gas outlet Inspect exhaust gas duct line in front of and after turbine for any combustion deposits foreign matter or residual water Clean and remove Inspect air supply line or filter silencer for any foreign matter Clean and remove Start up turbocharger oil circulation system at engine end Prepare turbocharger for operation as instructed in section Inspection work be...

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

Page 42: ...Copyright 2016 ABB All rights reserved February 2016 HZTL2485_EN Revision C Suggestion for noise insulation of the bellows 01 Compressor casing 04 Insulation pads 02 Bellows 05 Insulation mat at least 15 mm 03 Charge air duct scavenging air line 06 Sheet metal cover ...

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

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

Page 45: ...g and blow air through oil ports Clean nozzle ring and check for cracks and erosion Inspect and assess bearing parts and rotor Service work every 24000 36000 hours The replacement of bearing parts as well as the inspection and assessment of the rotor must be carried out by an ABB Turbocharging Service Station Disassemble turbocharger Measure clearances Clean the turbine and compressor wheels and i...

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

Page 47: ... 50000 100000 25000 50000 Gas outlet casing 50000 100000 35000 100000 Nozzle ring 35000 50000 25000 50000 Turbine diffuser cover ring 35000 50000 25000 50000 Other casings 100000 100000 Axial bearing components 24000 36000 24000 36000 Radial bearing components 24000 36000 24000 36000 Turbine blades due to wear 12000 Rotor components See the data on the rating plate GAS Gas Engine MDO Marine Diesel...

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

Page 49: ...inue to run at this reduced engine performance or turbocharger speed If the turbocharger surges continuously engine performance must be reduced further Measure the temperatures in the air and gas lines to and from the turbochargers and compare them with standard values If the engine can be stopped for a short time Inspect the air and gas lines as well as the turbocharger and eliminate any problems...

Page 50: ...r safety gloves against thermal risks Reduce engine performance to the idling speed then stop the engine Switch off the lubricating oil supply to the turbocharger Disconnect the cable connector from the speed sensor Screw out defective speed sensor Screw in a new speed sensor up to the limit block Observe the tightening torque see the table of tightening torques in the chapter entitled Disassembly...

Page 51: ...l rights reserved February 2016 HZTL2485_EN Revision C Stopping the engine 4 5 CAUTION Stopping the engine Heat in the turbocharger must be dissipated by the further circulating lubricating oil Allow the engine to continue running at idling speed for a further 10 minutes before stopping 4 5 ...

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Page 53: ...sual checks and cleaning to ensure that the turbocharger and its attached units function trouble free The external condition and how dirty the cleaning points specified in this chapter are must be established by visual checks at the specified intervals The safety precautions must be observed during all maintenance and servicing work The cleaning points described in the following are Filter silence...

Page 54: ...HZTL2485_EN Revision C Cleaning the filter silencer 5 2 Filter silencer and connecting rod 81265 Filter ring if provided 81136 Absorption segment 81269 Connecting rods 81137 Sheet metal covering 81266 Cover grid 81135 Filter silencer body 81272 Screwdriver 81273 Lock nut E Insert unit absorption segment sheet metal covering 5 2 5 2 1 ...

Page 55: ...ir is Clean filter strip every 500 hours of service or more frequently if necessary Unscrew and remove lock nuts 81273 Unscrew and remove screws 81272 for connecting rods 81269 Remove connecting rods 81269 Carefully remove cover grids 81266 Pull out insert units E bend open sheet metal coverings 81137 and then remove absorption segments 81136 Clean the absorption segments 81136 During cleaning ens...

Page 56: ...er injection line must now be refitted See also following section Fitting cleaning pipe Put cover grids 81266 uniformly into correct position Push connecting rods 81269 through clips on cover grids 81266 CAUTION If the connecting rods 81269 are not located correctly in their recesses on the filter silencer body 81135 the cover grids 81266 can twist and shift There is then a risk of foreign matter ...

Page 57: ...e filter silencer 5 2 Page 55 Copyright 2016 ABB All rights reserved February 2016 HZTL2485_EN Revision C Screw Tightening torque Nm 81272 20 Screw lock nuts 81273 onto screw 81272 and tighten to following torque Lock nut Tightening torque Nm 81273 40 ...

Page 58: ...ious kinds of dust Contamination of the compressor stage has a negative influence on the compressor efficiency and the charging pressure This results in higher exhaust gas temperatures and higher fuel consumption by the engine Contamination of the compressor can also increase rotor unbalance Under no circumstances is periodic cleaning of the compressor during operation a substitute for the service...

Page 59: ...jection pipe fitted in the filter silencer or the suction branch The water does not act as a solvent but the dirt deposit is removed by the mechanical impact of the droplets This is a very suitable process provided that the degree of contamination is not too high CAUTION Corrosion and deposits when cleaning Damage and impairment of turbocharger parts due to salt water and cooling water additives D...

Page 60: ...aning operation with XC2 Compressor wet cleaning operation with XC2 Maintain water pressure before connection to turbocharger during water injection time must be maintained as shown in table Cleaning parameters After cleaning wait at least 5 minutes to allow turbocharger to dry NOTICE If the cleaning process is unsatisfactory it can be repeated up to 2 times If the cleaning result is still not sat...

Page 61: ... process which has been tested and is recommended by ABB Turbo Systems the following prerequisites must be fulfilled Engine load 50 85 Start of cleaning cycle in accordance with following description for wet cleaning operation with XC3 Compressor wet cleaning procedure with XC3 It is mandatory to fulfil the operating condition prerequisites before cleaning compressors with XC3 Remove the sealing p...

Page 62: ...n injected After cleaning wait at least 5 minutes to allow the turbocharger to dry NOTICE If the cleaning operation is not satisfactory it may be repeated up to two times If the cleaning results are still not satisfactory after three attempts and the engine values are also unsatisfactory we recommend that you have the turbocharger inspected and cleaned by an official ABB Turbocharging Service Stat...

Page 63: ...anadate is as high as possible The amount of contamination increases over time which is why regular and correctly performed cleaning is important in order to remove the deposits that have formed Contaminated turbine components can cause a slight increase in charging pressure because of narrowing of the turbine cross section The contamination causes a drop in turbine efficiency and the engine tempe...

Page 64: ...rts due to salt water and cooling water additives Don t use salt water for cleaning but only clean fresh water NOTICE Components at the turbine end are not cleaned until the engine has been started or the engine load reduced The exhaust gas temperature must not exceed the value specified in the respective cleaning instructions see sections Prerequisites and Operating state CAUTION Non observance o...

Page 65: ... Don t use salt water for cleaning but only clean fresh water Recommended operating state for turbine wet cleaning The following operating state and prerequisites have been tested and approved by ABB Turbo Systems for the cleaning process The engine has just been started or the engine load has been reduced as far as possible best cleaning is achieved at a load level of roughly 10 to 15 As soon as ...

Page 66: ...ter Wet cleaning procedure for turbine during operation Meet prerequisites and operating state requirements without fail before cleaning Make sure water supply 01 is connected turned on and guaranteed Open drain pipe 08 09 if provided Switch over 3 way valve 04 from scavenging air mode to water supply NOTICE Set the required volume of water on the flowmeter as shown in the table in the following c...

Page 67: ...ing the cleaning process If a drainage system is not provided the injected volume of water can be controlled by a flowmeter in the water supply The maximum volume of water allowed in individual cases must be determined together with an ABB Turbocharging Service Station The influence of the cleaning water on peripheral equipment such as a boiler must be clarified by the operator The following must ...

Page 68: ...Page 66 Copyright 2016 ABB All rights reserved February 2016 HZTL2485_EN Revision C Wet cleaning parameters for turbine and nozzle ring Product Maximum temperature at start of cleaning process TTI C Injection time t i min Water flow rate per turbocharger at pWater 3 bar MW l min TPL76 C 430 10 37 ...

Page 69: ... using the cleaning method described in the following CAUTION Choosing cleaning tools Turbocharger components are sensitive to mechanical damage The use of needle guns or other impact tools for example damages the components Depending on the specification nozzle rings have protective coatings which can also be damaged Only use soft tools such as scouring cloths brushes or wire brushes In the event...

Page 70: ... mechanical risks 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 56001 Nozzle ring 63000 Turbine diffuser Place contaminated parts in hot water or in a liquid such as carbon remover so that the contam...

Page 71: ...nt Cleaning agents which contain chlorine attack metals Use only pH neutral cleaning agents which do not attack metals Observe safety data sheet CAUTION Water and contamination in the cartridge group If water or contamination penetrates the cartridge group this can impair the function of the turbocharger and damage parts inside the cartridge group Make sure that no water or contamination can enter...

Page 72: ...following To soften the layers of contamination on the turbine the cartridge group can be submerged vertically in a tank with liquid The cartridge group must be rotated to do this Two cranes or chain blocks must be used for the rotating operation Suspending the chain block directly from the crane and rotating the cartridge group is not permitted because of the risk of damage to the compressor whee...

Page 73: ...eyes in the lower push off threads and suspend from a second crane 3 Rotate cartridge group horizontally by lifting the second crane 4 When the cartridge group is horizontal secure one chain block from one of the upper push off threads using a swivel lifting eye and suspend from the second crane 5 Tighten chain block until entire cartridge group is suspended from second crane 6 Remove loop from fi...

Page 74: ...he lifting gear must not touch the compressor wheel at any time during rotation Choose appropriate lifting gear length 1 Suspend cartridge group from the two side suspension points on the crane using two lifting loops or Attach two swivel lifting eyes to the side and suspend the cartridge group from the crane using two lifting loops 2 Attach third lifting loop with swivel lifting eye to thread of ...

Page 75: ...en chain block until entire cartridge group is suspended from first crane 6 Remove loop from second crane CAUTION Selection of the cleaning agent Cleaning agents which contain chlorine attack metals Use only pH neutral cleaning agents which do not attack metals Observe safety data sheet Fill the tank with soaking liquid Only immerse the cartridge group until all blades are covered with cleaning ag...

Page 76: ...p the turbocharger function may be impaired and parts in the cartridge group may be damaged Place cartridge group on suitable wooden or metal supports Allow the layers of contamination on the turbine to soak for at least four hours Removing contamination WARNING Health hazard due to soot particles If soot particles enter the eyes or respiratory tract this can be harmful to health Avoid the formati...

Page 77: ...its lead to rotor unbalance This can result in bearing or turbocharger damage Remove all traces of contamination from the turbine After brushing off the contamination fill the tank with clean water not salt water Submerge the turbine of the cartridge group in clean water so that loose particles of contamination detach completely Lift the cartridge group Dry turbine and gap between turbine and seal...

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Page 79: ...charger Rotor unbalance Contact an ABB Turbocharging Service Station Damaged turbine or compressor Damaged bearing Rubbing of rotating parts Normal behaviour no malfunction Turbo charger Minor uniform wear around the periphery of rotor components caused by slight local rubbing of adjacent components is permissible The compressor blades and turbine blades are then shortened somewhat Certain toleran...

Page 80: ...or periodic surging Possible damage to components such as the compressor wheel turbine blades bearings and filter silencer Have the cause clarified immediately by an ABB Turbocharging service station and rectified Have components inspected for damage and if necessary replaced by an ABB Turbocharging service station Sporadic surge blows Surging of the turbocharger can occur during certain operating...

Page 81: ...rbo charger Rotor axial clearance too large Contact an ABB Turbocharging Service Station Reduction in speed Possible causes Elimination Engine Defects of connected cylinders when pulse charging Contact the enginebuilder Turbo charger Heavy contamination of the turbine Clean it Damaged rotor components or bearing Contact an ABB Turbocharging Service Station Pipes Defects such as leaks in the exhaus...

Page 82: ... it or contact the manufacturer Turbocharger Air starvation for example filter silencer clogged with dirt Clean it Compressor turbine contaminated Exhaust counterpressure too high Clean or repair the boiler or exhaust silencer Damaged or eroded turbine Contact an ABB Turbocharging Service Station Charge air cooler Cooler contaminated Clean it Cooling water volume too low Top up the water Entry tem...

Page 83: ... Replace the manometer Line to manometer leaking Repair the leak Contaminated filter silencer causing excessive loss of pressure Clean it Compressor turbine contaminated Damaged compressor turbine Contact an ABB Turbocharging Service Station Exhaust counterpressure too high Clean or repair the boiler or exhaust silencer Charge air pressure too high Engine performance and engine speed unchanged air...

Page 84: ... run down Possible causes Elimination Turbo charger Turbocharger contaminated Clean it Damaged bearing Contact an ABB Turbocharging Service Station Rubbing rotor Foreign object in turbocharger Run down time too short Possible causes Elimination Turbo charger Turbocharger contaminated Clean it Damaged bearing Contact an ABB Turbocharging Service Station Rubbing rotor Foreign object in turbocharger ...

Page 85: ...ause problems for the evaluation electronics This problem is eliminated by removing the gasket Defective sensor Contact ABB Turbocharging service station Measured speeds too high Dirty sensor tip The sensor tip is magnetic and can thus attract metal particles As a result the distance to the auxiliary bearing decreases which can lead to amplification of the noise component and consequently to fault...

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Page 87: ...5_EN Revision C Removal and installation Turbocharger weight 7 1 Lifting gear with a sufficient load limit must be used for removing and installing the turbocharger The following weight specification is the heaviest possibility This guide value can differ from data on the rating plate depending on the specification TPL76 C 4070 7 7 1 Weight kg ...

Page 88: ...ice plates An orifice plate for adjusting the oil pressure is fitted in each of the two oil inlet channels in the bearing casing When the cartridge group the bearing casing or the turbocharger is fitted to the engine it must be ensured that the orifice plates that are specified for the turbocharger have been installed in the two oil inlet channels Check correct installation of oil orifice plates S...

Page 89: ...chapter entitled Preliminary remarks Layout and functioning Inspect the lifting gear Fasten the lifting gear to the suspension lugs on the bearing casing and on the turbine end foot Unplug the cable connector on the speed sensor Unscrew the fixing screws on the feet Lift the turbocharger off the engine and set it down to one side WARNING If support for the turbocharger is not provided or is inadeq...

Page 90: ...bearing casing or the turbocharger is fitted to the engine it must be ensured that the orifice plates that are specified for the turbocharger have been installed in the two oil inlet channels Check correct installation of oil orifice plates Fit the turbocharger to the engine Tighten the fixing screws on the foot NOTICE The fastening specifications for the foot fixing screws are supplied to the eng...

Page 91: ...ons for assembly ABB Turbo Systems recommends that the casing positions are marked before disassembling the turbocharger Identifying assembly devices Not all assembly devices are marked with a part number They can be identified using the tool list This list is enclosed in the toolbox WARNING Maintaining assembly devices Assembly devices must be checked for damage before and after use Visually chec...

Page 92: ...ch turbochargers assemblies or individual components only to lifting gear which is in technically perfect condition and has sufficient load capacity Make sure the load is suspended properly on the crane hook Do not let anyone stand beneath a suspended load Wear safety gloves against mechanical risks Wear safety helmet Definition of terms Suspension point Defined load carrying point on a component ...

Page 93: ... to the next highest value Item Description TPL76 C 1 Filter silencer 280 2 Axial air suction branch 70 3 Radial air suction branch 120 4 Compressor casing internal part 220 5 Wall insert 220 6 Diffuser 45 7 Compressor casing external part 310 8 Cartridge group 900 9 Turbine diffuser 80 10 Nozzle ring 23 11 Radial gas inlet casing with segment connection 250 12 Segment 18 13 Radial gas inlet casin...

Page 94: ...016 ABB All rights reserved February 2016 HZTL2485_EN Revision C Complete compressor casing internal part TPL76 C 490 NOTICE The total weight of the complete internal part of the compressor casing includes the internal part of the compressor casing the diffuser and the wall insert Weight kg ...

Page 95: ...ter silencer or air suction branch 8 3 Disconnect all air lines ducts in accordance with engine builder s instructions Remove the insulation where necessary Loop the lifting gear around the air suction branch Unscrew the nuts 74027 and remove them together with their washers 74018 Remove the air suction branch and set it down to one side Install the air suction branch in reverse order 8 3 Installi...

Page 96: ...erved February 2016 HZTL2485_EN Revision C Remove insulation where necessary Pass lifting gear through rib on filter silencer and through eyelets at rear Unscrew nuts 74027 and remove them together with washers 74018 Remove filter silencer and it set down to one side Fit filter silencer in reverse order Removing filter silencer Fitting the filter silencer ...

Page 97: ...in injury Wear safety gloves Wear safety gloves against mechanical risks The axial clearance A must be measured before removing and after installing the cartridge group Measure and note the axial clearance A TPL76 C 0 43 0 69 CAUTION Clearances outside the tolerance Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts Have the component...

Page 98: ...s 76080 Fit four nuts 74027 complete with washers 74018 equally spaced around circumference and tighten Remove insulation from bearing casing Removing safety segments releasing casing Take nuts 90458 out of toolbox and screw them onto threaded studs of safety segments 76080 on internal part of compressor casing 76000 Tighten nuts 90458 to a maximum torque of 30 Nm The internal part of the compress...

Page 99: ...90190 will be fitted later Using press off screws 90900 push apart the compressor casing internal part 76000 until the lifting device 90190 90195 can be attached Slightly lift and then withdraw the compressor casing internal part including the wall insert and diffuser Attach the support angle 90025 using screws 90021 and nuts 74027 Put down the compressor casing internal part including the wall in...

Page 100: ...sing Carefully turn internal part of compressor casing complete with wall insert and diffuser about support angle 90025 and put onto underlay Set down casing on flange F Set down internal part of compressor casing in such a way that lifting device 90190 90195 can be removed WARNING Ensure that the shim does not slip Rest the internal part of the compressor casing only on flange F Check shim and ad...

Page 101: ...ll rights reserved February 2016 HZTL2485_EN Revision C Removing diffuser and wall insert Remove screws 76002 Remove diffuser 79000 using swivel lifting eyes 90235 Press away wall insert 77000 using press off screws 90230 and remove from internal part of compressor casing 76000 using swivel lifting eyes 90235 ...

Page 102: ...ng device 90190 90195 to external part of compressor casing 74000 using screws and secure to crane Remove screws 42280 Uniformly press away external part of compressor casing 74000 using press off screws 90900 and remove NOTICE Insulation on external part of compressor casing The insulation on the external part of the compressor casing does not need to be taken off when removing or fitting the cas...

Page 103: ...e plates An orifice plate for adjusting the oil pressure is fitted in each of the two oil inlet channels in the bearing casing When the cartridge group the bearing casing or the turbocharger is fitted to the engine it must be ensured that the orifice plates that are specified for the turbocharger have been installed in the two oil inlet channels Check correct installation of oil orifice plates Ver...

Page 104: ...emove Verbus Ripp washers 61051 Screw guide rod 90490 onto threaded stud X to balance cartridge group Press off cartridge group evenly using the press off screws 90900 in the holes provided CAUTION If the blades have insufficient or no clearance between the rotor and the casing the blades and the casing may be damaged Turn rotor to check that blades do not rub against turbine diffuser Withdraw car...

Page 105: ...BB All rights reserved February 2016 HZTL2485_EN Revision C Dismantling and installing the turbine diffuser and nozzle ring 8 6 Removing turbine diffuser Put assembly plate 90020 over strain bolts 61036 Insert extension A of torque spanner B through hole in assembly plate and loosen screws 61056 one after other Don t remove screws 61056 yet 8 6 ...

Page 106: ...0 Fit assembly plate 90020 over studs 61036 Screw nuts 61037 onto start of threads of studs 61036 to secure Remove remaining screws 61056 Press away turbine diffuser 63000 using press off screws 90901 and withdraw it until assembly plate 90020 touches nuts 61037 Loop lifting gear around turbine diffuser 63000 and secure to crane Remove nuts 61037 and assembly plate 90020 from studs Fully withdraw ...

Page 107: ...ews 56019 and remove Pull out nozzle ring CAUTION Fastening the nozzle ring When fitting the nozzle ring new screws 56019 and locking plates 56018 from the customer spare part set 97070 must be used CAUTION Clogged partial areas on the nozzle ring If a nozzle ring is found to be clogged over partial areas or covered by loose parts it is recommended that you have a turbine blade inspection includin...

Page 108: ...g the nozzle ring When fitting the nozzle ring new screws 56019 and locking plates 56018 from the customer spare part set 97070 must be used Push in nozzle ring 56001 as far as it will go up to cover of gas inlet casing Coat thread of screws 56019 with high temperature grease and fit with locking plates 56018 Tighten screws 56019 and bend locking plates 56018 over CAUTION Correct assembly The nozz...

Page 109: ...ting gear Align marking TOP with position of gas outlet flange and pay attention to where positioning pin is in gas outlet casing Fit turbine diffuser 63000 to guide studs 90320 Put assembly plate 90020 over strain bolts 61036 and guide studs 90320 Remove lifting gear and push in turbine diffuser Using three screws 61056 alternately and uniformly screw in turbine diffuser as far as it will go Inse...

Page 110: ... must be ensured that the orifice plates that are specified for the turbocharger have been installed in the two oil inlet channels Check correct installation of oil orifice plates Remove cover from oil connection Fit flange 42044 with new gasket 42045 and screws 42064 Check lifting gear and attach to bearing casing 42001 in such a way that cartridge group is suspended in a straight position Screw ...

Page 111: ...arance between the rotor and the casing the blades and the casing may be damaged Fit the remaining oiled nuts 61037 complete with new Verbus Ripp washers 61051 and tighten with pre tightening torque MV see chapter Table of tightening torques Tighten all nuts 61037 in a star pattern with tightening angle DW see chapter Table of tightening torques Remove the lifting gear Remove guide rod 90490 Screw...

Page 112: ...ts reserved February 2016 HZTL2485_EN Revision C Fitting external part of compressor casing Fasten lifting device 90190 90195 to external part 74000 of compressor casing and secure it with crane Fit O ring 42012 Fit external part of compressor casing 74000 and fasten using screws 42280 Remove lifting device 90190 90195 ...

Page 113: ...ng eyes 90235 into holes in wall insert 77000 Align mark A with notch B Fit centering screws 90230 in such a way that spigots on centering screws protrude maximum 5 mm Lower wall insert and align centering screws 90230 with threaded holes Remove swivel lifting eyes 90235 and centering screws 90230 Put the diffuser 79000 in place using the swivel lifting eyes 90235 Remove the swivel lifting eyes 90...

Page 114: ...ruary 2016 HZTL2485_EN Revision C Turning transporting internal part of compressor casing Fasten lifting device 90190 90195 to front side of flange F Carefully turn internal part of compressor casing 76000 complete with wall insert and diffuser about support angle 90025 and lift up vertically WARNING Ensure that the shim does not slip ...

Page 115: ... whether the nuts 90458 of the three safety segments have been tightened safety segments are in the not engaged position Fit O ring 76040 Remove the support angle 90025 screws 90021 and nuts 74027 Align the compressor casing internal part 76000 with the compressor casing external part as shown in the illustration on the next page Carefully insert the compressor casing internal part 76000 including...

Page 116: ...ights reserved February 2016 HZTL2485_EN Revision C NOTICE Align the compressor casing internal part 76000 with the notch see the arrow so that the notch is positioned at the rib of the compressor casing external part 74000 see the arrow Fully insert the compressor casing internal part 76000 Fit the studs 74026 74029 ...

Page 117: ...g of the two compressor casings 74000 76000 is not guaranteed Fit four nuts 74027 complete with washers 74018 equally spaced around circumference and tighten Unscrew nuts 90458 on threaded studs of safety segments 76080 on internal part of compressor casing 76000 The internal part of the compressor casing 76000 is now secure relative to the external part 74000 NOTICE Note the control dimension s T...

Page 118: ...has sharp edges which can cause injuries Wear safety gloves Wear safety gloves against mechanical risks Measure and note axial clearance A TPL76 C 0 43 0 69 CAUTION If the axial clearance A is out of tolerance an official ABB Turbo Systems service station must be contacted Connect oil lines and all air lines in accordance with engine builder specifications Fit filter silencer or air suction branch...

Page 119: ... loose parts it is recommended that you have a turbine blade inspection including a crack inspection carried out by an ABB Turbocharging Service Station The fitted spiral wound gasket 61050 may be used only once Make ready a new spiral wound gasket 61050 Disassembly Remove insulation from gas inlet casing 51001 and disconnect cleaning pipe if provided Secure gas inlet casing using lifting gear CAU...

Page 120: ...s reserved February 2016 HZTL2485_EN Revision C Remove screws 61044 and segments 51012 Undo and remove screws 61044 Pull gas inlet casing 51001 complete with nozzle ring 56001 away from gas outlet casing 61001 CAUTION Use suitable underlays when putting down gas inlet casing Remove gasket 61050 Segment connection Flange connection 1 If present ...

Page 121: ...nd remove Remove nozzle ring 56001 Nozzle ring assembly Carefully clean grooves and contact surfaces of the casings and keep them free of metal chips Keep grooves and spiral wound gasket free of oil and grease CAUTION Fastening the nozzle ring When fitting the nozzle ring new screws 56019 and locking plates 56018 from the customer spare part set 97070 must be used Push in nozzle ring 56001 as far ...

Page 122: ...ittle instant adhesive for example Loctite 454 Gel applied at three equally spaced points Position gas inlet casing complete with nozzle ring on gas outlet casing 61001 Tightening of segment connection NOTICE Radial gas inlet casing with segment 51012 In the case of the radial inlet casing with segments the segments are positioned by a pin in the slot on the casing The centering bolt 90177 is alwa...

Page 123: ...ree segments is there a roll pin as an aid when positioning the gas inlet casing This segment fits in only one position in the gas inlet casing note the circle in the illustration Consequently begin with this segment Put remaining segments 51012 in place on gas inlet casing 51001 and fit them loosely using screws 61044 Replace centering bolts 90177 with screws 61044 Collars C of segments 51012 mus...

Page 124: ...itioning numbers must be marked on the component This enables simple and efficient tightening Tightening TPL76 C Step 1 Screw in all screws hand tight Step 2 140 Step 3 280 Tightening TPL76 C Step 1 Screw in all screws hand tight Step 3 280 Beginning with screw 1 tighten all screws in a clockwise direction with tightening torque from step 3 Remove lifting gear from gas inlet casing 51001 Connect c...

Page 125: ...ved February 2016 HZTL2485_EN Revision C Tightening flange connection Fit screws 61044 Tighten screws 61044 in accordance with following procedure and in following order Flange connection Tighten screws crosswise NOTICE Screw tightening sequence The screw positioning numbers must be marked on the component This enables simple and efficient tightening ...

Page 126: ...3 280 Tightening TPL76 C Step 1 Screw in all screws hand tight Step 3 280 Beginning with screw 1 tighten all screws in a clockwise direction with tightening torque from step 3 Remove lifting gear from gas inlet casing 51001 Connect cleaning pipe if present and attach insulation to gas inlet casing 51001 Tightening torques for screws 61044 Nm with spiral wound gasket Tightening torques for screws 6...

Page 127: ...Operation Manual TPL76 C Disassembly and assembly 8 Dismantling and fitting nozzle ring at turbine end 8 8 Page 125 Copyright 2016 ABB All rights reserved February 2016 HZTL2485_EN Revision C ...

Page 128: ...unit is assembled 2 a Tighten three nuts at 120 intervals to pre tightening torque MV lightly oil contact surface of nut b Tighten the remaining nuts with pre tightening torque MV c Tighten all nuts in a star pattern with tightening angle DW 3 After putting a new Verbus Ripp washer under each nut 8 tighten with pre tightening torque of MV 80 Nm then mark the 0 point and tighten under tightening an...

Page 129: ...d February 2016 HZTL2485_EN Revision C Item Part number TPL76 C 1 82005 M16 x 1 5 45 3 76002 M6 10 4 74027 With washer M18 170 5 74026 74029 M18 40 6 42280 M18 280 7 61036 61051 VR 1 M18 40 8 61037 2 3 M18 MV 80 DW 90 9 42059 42064 M16 105 17 61044 M18 280 21 61056 M18 280 22 56019 M10 50 29 86505 M18x1 5 150 Tightening torques Nm ...

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Page 131: ... and depending on the situation stop the engine Seal oil leaks Soak up oil and dispose of in an environmentally compatible manner Wear safety gloves against thermal risks CAUTION Directives for taking out of operation Serious damage to engine or property can be caused by non compliance with the directives for locking blanking off the turbocharger on the engine Follow the directives of the enginebu...

Page 132: ...is is sometimes requested by customers As operation with a locked rotor is only brief and the loads are low in these cases subsequent removal of the rotor is not necessary CAUTION During operation of the engine with a blocked turbocharger the lubricating oil system must remain connected to this turbocharger also and be turned on if the gas inlet cannot be blocked See section Further measures and i...

Page 133: ...Locking rotor Part no TPL76 C 74027 M18 135 Nm 94006 M8 25 Nm NOTICE Carry out work as described in the chapter Disassembly and assembly Remove silencer or air suction branch Insert lifting device 90427 into compressor wheel Twist screws 94006 into free threaded holes in compressor wheel and tighten to values shown in Table of tightening torques Table of tightening torques ...

Page 134: ...mbly disassembly device 90020 over studs 74026 and lifting device 90427 Turn compressor wheel until holes in lifting device 90427 align with holes in assembly disassembly device 90020 Fasten assembly disassembly device to lifting device 90427 using screws 94006 Secure assembly disassembly device 90020 to compressor housing by screwing nuts 74027 onto studs 74026 See also chapter Table of tightenin...

Page 135: ...and the air duct on the engine side must be closed off If this is not done the undamaged turbocharger can race under no load and run at overspeed Depending on the engine turbocharging system more or less powerful pulses from the exhaust gas system act on the locked rotor The locking device is then heavily stressed particularly in the case of pulse charging turbine casing with more than one gas inl...

Page 136: ...ion C Fit cover plate 9 3 NOTICE The cover plate material General structural steel in accordance with DIN EN 10025 2 must be manufactured in house according to the drawing Product B1 B2 B3 B4 B5 B6 B7 B8 TPL76 C 13 470 50 50 9 12 8 82 Product Ø 1 Ø 2 Ø 3 Ø 4 Ø 5 Ø 6 TPL76 C 915 990 950 20 28 20 Product 1 2 3 TPL76 C 4 x 90 37 5 24 x 15 9 3 Cover plate dimensions mm ...

Page 137: ...ut of operation at short notice 9 Fit cover plate 9 3 Page 135 Copyright 2016 ABB All rights reserved February 2016 HZTL2485_EN Revision C NOTICE Carry out the work as described in the chapter Removal and fitting Remove cartridge group ...

Page 138: ...er plate 9 3 Page 136 Copyright 2016 ABB All rights reserved February 2016 HZTL2485_EN Revision C Close off opening in gas outlet casing using cover plate Fasten cover plate using spacer sleeves and nuts 61037 CAUTION Shut off the supply of lubricating oil to the turbocharger ...

Page 139: ...uilder s instructions 4 stroke engine with several turbochargers No further measures are necessary on engines with separate air and exhaust gas receivers The engine can be operated as a naturally aspirated engine according to the engine builder s instructions The air line must be closed off at the engine end because the undamaged turbochargers build up a receiver pressure CAUTION The engine can be...

Page 140: ...ocharger Shut off compressor casing outlet gas inlet and gas outlet by fitting cover plates NOTICE In this respect refer to the engine manufacturer s instructions Bypass the turbocharger 9 5 CAUTION Shut off the lubricating oil supply to the turbocharger This applies to engines with one turbocharger only The connections are ready and pipes for the bypass are available Fit bypass around turbocharge...

Page 141: ...out of operation and this is circulated by the prelubrication pump no measures have to be taken Any remaining old engine oil will thus be flushed away and the bearing sections largely protected against corrosion Mothballing measures If the total acid number TAN is greater than 2 mg KOH g the following mothballing measures are necessary after taking an engine out of operation Remove turbocharger Ro...

Page 142: ... out of operation for up to 12 months under Mothballing measures for the measures always necessary when mothballing turbocharger parts If the turbocharger remains mounted on the engine refer to the section Taking out of operation for up to 12 months under Rotating the rotor in stack draught If the entire turbocharger is removed or if the turbocharger is re assembled next to the engine using the in...

Page 143: ...e of leather Wear safety goggles Wear a respiratory mask to protect against particles Wear safety gloves against mechanical risks Disposal must be environmentally compatible professional and in compliance 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 materi...

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Page 145: ...on and part number Spare parts can be ordered from an official ABB Turbocharging Service Station If different design versions have not been taken into consideration in this document please contact an ABB Turbocharging Service Station CAUTION Storage of spare parts All spare parts ordered with the turbocharger must be kept complete and ready for use Parts showing signs of rust should be carefully c...

Page 146: ... 97070 is required for the work described in this operation manual These parts are available only as a complete set Quantity Description Part number 1 O ring 42012 1 Gasket 42041 2 Gasket 42045 2 Hexagon head screw 42059 42064 3 Locking plate 56018 3 Hexagon head screw 56019 3 Hex nut 61037 12 Hexagon head screw 61044 61056 17 Verbus Ripp Washer 61051 3 Socket screw 76002 1 O ring 76040 1 O ring 7...

Page 148: ...n Manual TPL76 C Spare parts 12 View of turbocharger with part numbers 12 2 Page 146 Copyright 2016 ABB All rights reserved February 2016 HZTL2485_EN Revision C View of turbocharger with part numbers 12 2 12 2 ...

Page 149: ...4 in customer spare part set Hexagon head screw 61050 in customer spare part set Gasket 61051 in customer spare part set Verbus Ripp Washer 61056 in customer spare part set Hexagon head screw 61065 Gasket 61066 Blind flange 61067 Hexagon head screw 63000 Turbine diffuser 68001 Foot at compressor end 68002 Foot at turbine end 68006 Cup spring 68007 Bush 61079 Gasket 74000 Compressor casing external...

Page 150: ...ABB Turbo Systems AG Bruggerstrasse 71a CH 5400 Baden Switzerland ABB ...

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