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Operation Manual

ABB  Turbocharging

ABB Turbo Systems Ltd
CH 5401 Baden

Type

TPS48-F33

HT842885

n

Mmax

1027

t

Mmax

650

n

Bmax

1007

t

Bmax

620

1/s

°C

SGAK02

00180

12

50

50

Year

2017

made in Switzerland

Application according to

the Operation Manual

kg 

HZTL2412 English

TPS48-F33

Original Operation Manual

Summary of Contents for HT842885

Page 1: ...tems Ltd CH 5401 Baden Type TPS48 F33 HT842885 nMmax 1027 t Mmax 650 nBmax 1007 t Bmax 620 1 s C SGAK02 00180 12 50 50 Year 2017 made in Switzerland Application according to the Operation Manual kg HZTL2412 English TPS48 F33 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: ...ing plate 1 8 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 Deflagration on gas engines 2 9 Periodic checking of the pressure vessel 2 10 Lifting loads 3 Start up 3 1 Oil supply 3 2 Inspe...

Page 4: ...Transport 7 2 Turbocharger weights 7 3 Remove the turbocharger 7 4 Installing the turbocharger 8 Disassembly and assembly 8 1 Introduction 8 2 Module weights 8 3 Disassembling and assembling turbocharger 8 4 Axial clearance A and radial clearance B 8 5 Radial clearances N and R 8 6 Table of tightening torques 9 Taking out of operation 9 1 Shutting down the turbocharger 10 Mothballing the turbochar...

Page 5: ... Turbo Systems and to use it as intended It provides important information in order that the turbocharger can be op erated safely correctly and efficiently This Operation Manual complements and expands existing national regu lations concerning work safety and accident prevention Target group This Operation Manual is intended for engineers and qualified mechanics who are responsible for operating t...

Page 6: ...2412_EN Revision F Layout and function 1 2 1 Suction branch filter silencer 8 Gas outlet flange 2 Compressor casing 9 Nozzle ring 3 Diffuser 10 Turbine casing 4 Bearing casing 11 Turbine end bearing flange 5 Axial thrust bearing 12 Compressor end bearing flange 6 Radial plain bearing visible only at turbine end 13 Compressor wheel 7 Turbine 1 2 ...

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

Page 8: ...nufacturer accepts no liability for other applications If it is used otherwise ABB Turbo Sys tems reserves the right to reject all warranty claims This turbocharger was built according to state of the art technology and is operationally safe according to recognised safety regulations WARNING Improper operation and maintenance of the turbocharger can result in danger to life and limb of the user or...

Page 9: ... 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 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 glo...

Page 10: ...B Turbocharging Service Station and repacked Inspect the package for damage If the package is damaged the tur bocharger or cartridge group must be inspected by an ABB Turbo charging 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 Re...

Page 11: ... also 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 en gine in the event of alterations affecting safety or of corresponding op erating behaviour The fault must ...

Page 12: ... original 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 o...

Page 13: ...t are not rele vant 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 T...

Page 14: ...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 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 Syst...

Page 15: ...se agreed with the enginebuilder 02 Turbocharger operating limits during operation 03 Inspection interval of plain bearings in 1000 h 04 Replacement interval of compressor in 1000 h 05 Replacement interval of turbine in 1000 h 06 Customer part number 07 Designation of the special design 08 Weight of turbocharger in kg 09 Turbocharger type 10 Serial number 11 Year of construction of turbocharger 1 ...

Page 16: ...ably shorten the recommended replacement intervals In such cases we recommend that you contact the nearest official ABB Turbocharging service station nMmaxand tMmax normally apply only when running at overload 110 during tri als 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 ...

Page 17: ...eserved September 2016 HZTL2412_EN Revision F Contact information 1 8 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 8 ...

Page 18: ......

Page 19: ...rger itself and its accessories originate from the operating and auxiliary materials used are the consequence of insufficient observance of the safety instruc tions 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 t...

Page 20: ... 2 2 Page 18 Copyright 2016 ABB All rights reserved September 2016 HZTL2412_EN Revision F CE conformity 2 2 Information ABB turbochargers fulfil Directive 2006 42 EC on machinery and are con sidered partly completed machinery in the sense of Article 2 g 2 2 ...

Page 21: ...of mandatory signs 2 3 To be worn at all times Protective clothing Safety footwear to protect against mechanical hazard and risk of falling To be worn according to the specific work Safety glasses Safety goggles Safety gloves to protect against Mechanical hazard Chemical hazard Thermal hazard Respiratory mask to protect against Dusts Gases Safety helmet Ear protection 2 3 ...

Page 22: ...n 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 observed at all times CAUTION Definition of caution Serious machine or property damage may occur if work and operating instructions marked with this symbol ...

Page 23: ...ing plates are not present at the intended places or are not legible then proceed as follows Order new warning plates from ABB Turbocharging Service Stations Remove unreadable warning plates Clean and degrease surfaces provided for warning plates Attach new warning plates Uninsulated turbochargers When uninsulated turbochargers are delivered to the engine builder the warning plates must be subsequ...

Page 24: ... 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 mate rials 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 ob stacles on the floor Keep the floor equipment and the turbocharger clean Hav...

Page 25: ...he separate burst pro tection 57200 must be fitted before operation See View of tur bocharger showing part numbers 126 Before starting work carry out visual inspection of working area Remove any obstacles and objects lying around Before start up commissioning check all pipes from and to turbo charger for damage and leaks Don t work in any way that could impair safety when working on turbo charger ...

Page 26: ...charger the engine must 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...

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

Page 28: ...level is above 85 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 op erating materials lubricating oil become hot The surface temperature is dependent on the effectiveness of the insulation being used The tem perature can become high enough so that it falls into ranges where burns ar...

Page 29: ...gainst hot turbocharger surfaces is compulsory Wear safety gloves to protect against thermal hazards Hazards due to operating and auxiliary materials Operating and auxiliary materials are substances used for operation or the execution of maintenance work Oils greases coolants cleaning agents and solvents acids etc can be regarded as hazardous materials Operat ing and auxiliary materials can be com...

Page 30: ...e atmosphere or contamination of the ground and water due to improper disposal can lead to environmental damage Handle operating and auxiliary materials carefully Heed the instructions for use safety data sheets and hazard notices on the containers of the operating and auxiliary materials Wear appropriate protective clothing Avoid inhalation and contact with the skin Ensure that the work space is ...

Page 31: ...s only in the work area Take particular care when removing old insulating materials Dispose of insulating materials properly and in an environmentally compatible way in accordance with applicable local regulations Wear safety goggles Wear a respiratory mask to protect against dusts Wear safety gloves to protect against chemical hazards Use only suitable non combustible insulating materials Ensure ...

Page 32: ...erved September 2016 HZTL2412_EN Revision F 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 specialists Heed any country specific regulations ...

Page 33: ...urbo Systems recommends verifying the following points on the turbocharger Position of the turbine and compressor casings to the bearing casing Shifting of the bearing casing in relation to the bracket Cracks in casings If during external inspection anomalies are found or if a particularly strong deflagration event has taken place it is also recommended to check the bearings of the turbochargers b...

Page 34: ...e so 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 ves sel 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 th...

Page 35: ...nd beneath a suspended load Wear safety gloves to protect against mechanical hazards 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 respec tive handling steps Before attaching slings allow turbocharger components to cool down...

Page 36: ......

Page 37: ...tion CAUTION Depending on the turbine specifications and bearings used varying amounts of contaminants have to be filtered out of the lubricating oil to avoid dangerous wear of the bearing parts The standard oil filter specification for the turbocharger is 34 µm This means that contaminants larger than 0 034 mm must be filtered out of the oil with a separation efficiency 99 Fit an accessory filter...

Page 38: ...issible oil inlet vis cosities and oil inlet temperatures are shown in the following chart 1 Kinematic viscosity mm2 s cSt 2 Oil inlet temperature C A Permissible range CAUTION Falling below the minimum oil inlet temperature Serious machine or property damage can be caused by excessively high oil viscosity and the resulting lack of oil in the bearings Do not allow the oil inlet temperature to fall...

Page 39: ...nsure trouble free operation Status for operation Oil pressure in front of turbocharger bar Normal operation 2 0 4 5 Engine start cold oil permissible for maximum 15 minutes 8 0 Engine idling 0 2 Pre and post lubrication engine stopped 1 0 CAUTION Prelubrication Serious machine or property damage might result if the turbocharger is not supplied with oil when the engine is starting Activate prelubr...

Page 40: ...utlet The oil temperature at the outlet depends mainly on lubricating oil temperature and pressure at the oil inlet engine load and turbocharger speed exhaust gas temperature The maximum permissible oil temperature at the outlet is listed in the fol lowing table The specified oil outlet temperature must be regarded as an alarm value for turbocharger operation and be monitored in accordance with st...

Page 41: ... 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 lubricat ing system special running in filters must be used Check oil pressure in oil supply lines CAUTION Prelubrication Serious machine o...

Page 42: ...emperature 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 commis...

Page 43: ... duct 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 re move 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...

Page 44: ......

Page 45: ...m the 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 acoust...

Page 46: ... 44 Copyright 2016 ABB All rights reserved September 2016 HZTL2412_EN Revision F 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 47: ...rvals 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 Sys tems NOTICE Service inspection after 5 years To prevent age and stoppage related machi...

Page 48: ...th instructions on rating plate In general after 8000 12000 hours of operation Rotor and bearing parts must be inspected and assessed by an ABB Turbo charging Service Station The following work can be carried in preparation Remove cartridge group as described in chapter Disassembly and as sembly Measure clearances Clean turbine and compressor casings and check them for cracks and erosion corrosion...

Page 49: ...e following operating data and measured values must be entered regu larly in the engine manufacturer 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 ...

Page 50: ...and the replacement interval for those non rotating components that are exposed to hot gases Decisive in this respect are various influencing parameters which can drastically shorten the replacement intervals of these parts in extreme cases During the specified periodic service work the individual components are inspected for wear and if necessary replaced Expected replacement intervals h GAS MDO ...

Page 51: ...e following influences Fuel quality and preparation Load profile thermal load cycles also starts stops emergency shut downs Gas inlet temperature Frequency and execution of turbine and compressor cleaning Turbocharger specification System specific operating conditions operating point combustion quality composition of exhaust gas For bearing parts Lubricating oil quality oil filtration condition of...

Page 52: ... monitoring of the turbo charger 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 86505 A Speed sensor cable not integrated 86526 F I converter 86505 B Speed sensor cable integrated 86528 Tachometer 86515 A Cable connector to 86505 A 01 Screw plug 86515 B Cable connector to 865...

Page 53: ...eded the following steps must be carried out Reduce engine performance immediately until the highest turbo charger speed no longer exceeds 70 of nBmax If the engine cannot be stopped continue 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...

Page 54: ...atures exceeding 100 C Wear safety gloves when removing the cable connector and speed sensor Wear safety gloves to protect against thermal hazards 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 limi...

Page 55: ... Sealing the speed sensor The speed sensor is designed with a sealing lip and does not require an additional gasket when fitted Connect cable connector to speed sensor Switch on lubricating oil supply to turbocharger Failure of speed measuring system Possible reasons for failure of the speed measuring system are described in the chapter Troubleshooting 4 4 3 ...

Page 56: ... be dissipated by the further circulating lubricating oil Post lubricate for 15 20 minutes Maintain oil pressure of 0 5 1 0 bar for post lubrication CAUTION Stopping the engine of water cooled turbocharger version Heat in the turbocharger must be dissipated Allow turbocharger cooling water to run for 15 20 minutes after stopping engine Allow oil lubrication to continue running until rotor comes to...

Page 57: ...eaning If mechanical cleaning is carried out too often this can lead to damage and corrosion on the components If cleaning during operation is not sufficient to achieve acceptable values regarding thermal load and engine performance mechanical cleaning of certain spots can be carried out Perform mechanical cleaning especially of the cartridge group only once within the service interval NOTICE Clea...

Page 58: ...onsumption Increased rotor unbalance Periodic cleaning of the compressor during operation prevents or delays any major increase in contamination But it never replaces the regular service work where the turbocharger is completely dismantled and the compressor is mechanically cleaned NOTICE If the coating of dirt is very thick and hard the compressor can only be cleaned manually when disassembled Th...

Page 59: ...not too high CAUTION Corrosion and deposits when cleaning Damage and impairment of turbocharger parts due to salt water and cooling water additives Don t use salt water for cleaning but only clean fresh water CAUTION The injection pipe must on no account be connected directly via a cock to a water pipe or a dosing vessel larger than the one supplied This prevents uncontrolled volumes of water ente...

Page 60: ... externally mounted water vessel is suitable only for those applications where a negative pressure exists in front of the compressor wheel not used for blowers connected in front of the compressor or high pressure compressor stages with two stage charg ing Operating state prerequisites for cleaning compressor with XC1 NOTICE To be able to carry out a satisfactory cleaning process that has been tes...

Page 61: ...the cleaning cycle until a stabilisation period of at least 10 minutes has elapsed NOTICE Whether or not cleaning has been successful can be seen from the charging or flushing pressure and also from the exhaust gas tempera tures If the cleaning process is unsatisfactory it can be repeated up to 2 times If the cleaning result is still not satisfactory after three attempts and the engine values are ...

Page 62: ...ecome stuck in contamination deposits Experience with turbocharger operation shows that the intervals between overhauls can be extended if cleaning while in operation is carried out pe riodically Wet cleaning the turbine as described below should be used for 4 stroke applications when there are heavy deposits from for example HFO Under no circumstances is periodic cleaning of the turbine during op...

Page 63: ...ng method NOTICE Approval by engine manufacturer The prerequisite for wet cleaning is that the engine manufacturer ap proves the method and his instructions are followed Wet cleaning methods Process with short water injection time 3 x 30 seconds cleaning The cleaning process with short water injection time is used for turbo charger designs without additional sealing by means of C rings The process...

Page 64: ...en cleaning the temperature in front of the turbine will rise and can heavily stress the material of turbine components The temperature at the turbine inlet can be up to 100 C higher than the exhaust gas tem perature after the cylinder This should be taken into consideration when setting the operating point before cleaning Don t exceed maximum temperature in front of turbine when clean ing CAUTION...

Page 65: ...ed and is approved by ABB Turbo Systems Characteristic component Conditions short water injection time long water injection time Engine load guide value 20 40 Turbine inlet temperature TTE before water injection 350 400 C 350 430 C Water supply ensured Water pressure overpres sure over atmosphere pWT 2 0 bar 1 5 bar If necessary engine performance must be reduced to maintain these conditions The c...

Page 66: ...ing phase before increasing engine load again This completes the turbine cleaning process Cleaning parameters during the process TPS Temperature in front of the turbine during cleaning C Water volume flow 1 dm3 min Injection time min Pause between injections min 44 450 4 5 0 5 3 x 3 48 6 52 8 57 11 61 17 5 1 corresponds to a water pressure pWT of 2 0 bar overpressure over at mosphere CAUTION Maxim...

Page 67: ...rbine cleaning process Cleaning parameters during the process TPS Temperature in front of the turbine during cleaning C Water volume flow 1 dm3 min Injection time min Stabilising phase before after water injection min 44 530 2 5 10 10 48 4 52 5 5 57 8 5 61 12 1 corresponds to a water pressure pWT of 1 5 bar overpressure over at mosphere CAUTION Maximum temperature in front of turbine during cleani...

Page 68: ...the specification nozzle rings and turbine casings have protective coatings which can also be damaged Only use soft tools such as cloths brushes or wire brushes In the event of heavy contamination the cleaning methods that have been described such as soaking can be repeated until a satisfactory result has been achieved Dispose of dirty water and cleaning agents in an environmentally com patible ma...

Page 69: ...titled Disassembly and Assembly Cleaning the filter ring if provided Remove filter ring 81265 Clean filter ring 81265 as required or every 500 operating hours and replace after the fifth cleaning operation at the latest The degree of contamination of the filter ring depends on the cleanli ness of the air that is drawn in Wash filter ring 81265 using water containing light duty detergent or if very...

Page 70: ...orption segments 81136 are only cleaned with a mild jet of compressed air soft brush or a damp cloth Have absorption segments which are heavily contaminated replaced by an official ABB Turbocharging Service Station Fitting the filter silencer Insert the absorption segments 81136 into the sheet metal coverings 81137 Bend the sheet metal coverings 81137 back into their original shape and insert them...

Page 71: ...onal protective equipment PPE according to the material safety data sheet Comply with local legislation Wear safety goggles Wear safety gloves to protect against chemical hazards Wear a respiratory mask to protect against gases The following performance relevant parts can be cleaned according to the following description 72000 Compressor casing 77000 Wall insert 79000 Diffuser Clean the components...

Page 72: ...ment PPE according to the material safety data sheet Comply with local legislation Wear safety goggles Wear safety gloves to protect against chemical hazards Wear a respiratory mask to protect against gases Baked layers of contamination for example from heavy fuel oil or coked oil occur at the turbine end The following parts which are relevant in terms of performance can be cleaned in accordance w...

Page 73: ...o operation again immediately after cleaning parts may corrode Re install and use the cartridge group immediately after cleaning Compressor wheels or turbines may be heavily contaminated due to heavy fuel oil operation or coked oil Such contamination may possibly no longer be removed through cleaning during operation and must be cleaned mechanically during the standard service intervals see chapte...

Page 74: ...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 into the cartridge group Clean compressor wheel with a cloth or soft brush soaked in water with household detergent Do not use any wire brushes Dry the compressor wheel and the gap between the compressor and the...

Page 75: ...eaning of the turbine are described below Product A mm B mm C mm TPS44 91 15 173 TPS48 108 17 205 TPS52 128 20 245 TPS57 157 25 300 TPS61 187 30 357 To soak the layers of dirt on the turbine the cartridge group can be sub merged vertically in a tank 02 with liquid Place the tank 02 in a larger container 03 so that the excess liquid can be collected CAUTION Selection of the cleaning agent Cleaning ...

Page 76: ...e va pours can be produced which are hazardous to health Observe the information in the material safety data sheet Wear a respiratory mask according to material safety data sheet CAUTION Water and dirt in the cartridge group If water or dirt gets into the cartridge group the turbocharger function may be impaired and parts in the cartridge group may be damaged Place the cartridge group on suitable ...

Page 77: ...spiratory tract this can be harmful to health Avoid the formation of dust Vacuum up dust with a suitable vacuum cleaner Wear a respiratory mask to protect against particles P1 or P2 mask Wear safety goggles Wear safety goggles Wear a respiratory mask to protect against dusts Wear safety gloves to protect against mechanical hazards Raise the cartridge group and align horizontally Remove dirt manual...

Page 78: ...nation deposits lead to rotor un balance This can result in bearing or turbocharger damage Remove all traces of contamination from the turbine After brushing off the contamination fill the tank 02 with clean water not salt water Submerge the turbine of the cartridge group in clean water so that loose particles of dirt detach completely Raise the cartridge group and align horizontally Clamp the par...

Page 79: ...rbocharger Rotor unbalance Contact an ABB Turbocharg ing Service Station Damaged turbine or compressor Damaged bearing Rubbing of rotating parts Normal behaviour no malfunction Turbocharger Minor uniform wear around the periphery of rotor components caused by slight local rubbing of adjacent components is per missible The compressor blades and turbine blades are then shortened somewhat Certain tol...

Page 80: ...ged or periodic surging Possible damage to components such as the compressor wheel tur bine blades bearings and filter silencer Have the cause clarified immediately by an ABB Turbocharging ser vice 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 ope...

Page 81: ...ter Turbocharger Rotor axial clearance too large Contact an ABB Turbocharging Service Station Reduction in speed Possible causes Elimination Engine Defects of connected cylin ders when pulse charging Contact the enginebuilder Turbocharger 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 e...

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

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

Page 84: ...ine performance losses Possible causes Remedy Turbocharger Heavy fouling of the com pressor components Clean compressor Optimize oil separation Increased vibrations com pressor blade damage Correct the feed of ventilation gases according to instructions of enginebuilder Reduced fatigue strength of the compressor wheel compressor blade failure Possible causes Remedy Turbocharger Material of compres...

Page 85: ...uring run down Possible causes Elimination Turbocharger Turbocharger contaminated Clean it Damaged bearing Contact an ABB Turbocharg ing Service Station Rubbing rotor Foreign object in turbocharger Run down time too short Possible causes Elimination Turbocharger Turbocharger contaminated Clean it Damaged bearing Contact an ABB Turbocharg ing Service Station Rubbing rotor Foreign object in turbocha...

Page 86: ... cause problems for the evaluation electronics This problem is eliminated by removing the gasket Defective sensor Contact an ABB Turbocharging Service Sta tion Measured speeds too high Contaminated sensor tip The sensor tip is magnetic and can thus at tract metal particles As a result the dis tance to the signal generating sealing disc is reduced which can lead to amplification of the noise compon...

Page 87: ...er 2016 HZTL2412_EN Revision F Removal and installation Transport 7 1 Suspension of uninsulated turbocharger Turbocharger with oil cooled bearing casing Complete turbocharger with gas outlet casing Suspension of insulated turbocharger Turbocharger with oil cooled bearing casing Complete turbocharger with gas outlet casing 7 7 1 ...

Page 88: ...F Turbocharger weights 7 2 Lifting gear with a sufficient load limit must be used for removing and in stalling the turbocharger The following weight specification is the heaviest possibility This guide value can differ from data on the rating plate de pending on the specification TPS44 kg TPS48 kg TPS52 kg TPS57 kg TPS61 kg 120 180 250 410 650 Turbocharger weights 7 2 ...

Page 89: ...ve hard insulation as follows Remove screws and sheet metal B from the bearing casing insula tion Remove the remaining screws from the bearing casing insulation A Pull the bearing casing insulation up and off The bearing casing insu lation can be compressed to facilitate the removal process Unplug the cable connector from the speed sensor Attach lifting gear to bearing casing If a gas outlet bend ...

Page 90: ... µ 0 12 for tightening torque Product Through hole in bearing casing mm Thread size mm Tightening torque Nm Strength class in acc with DIN ISO 898 TPS44 17 M16 230 10 9 12 9 TPS48 17 M16 230 10 9 12 9 TPS52 21 M20 455 10 9 12 9 TPS57 21 M20 455 10 9 12 9 TPS61 25 M24 780 10 9 12 9 Attach lifting gear to bearing casing If a gas outlet manifold is provided sling lifting gear around it addition ally ...

Page 91: ... 2016 HZTL2412_EN Revision F If present Fit speed sensor and plug in cable connector Adapt and fit bearing casing insulation A Adapt and fit sheet metal B of bearing casing insulation Version with water cooled bearing casing Remove the screw plugs from the water connections and fit the water pipes in accordance with the enginebuilder s instructions ...

Page 92: ......

Page 93: ...roup can lead to serious machine damage ABB Turbo Systems recommends having further work carried out on ly by trained personnel from an ABB Turbocharging Service Station NOTICE Marking casing positions 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 numb...

Page 94: ...ing else is described the screws and nuts of the assembly devices must be tightened down firmly WARNING Suspended loads Loads not suspended in compliance with regulations may lead to per sonal injury or accidents with fatal consequences Attach turbochargers assemblies or individual components only to lifting gear which is in technically perfect condition and has sufficient load capacity Make sure ...

Page 95: ...or the applications described Lifting gear Equipment for lifting and transporting loads ropes chain hoists cranes Lifting gear is not supplied by ABB Turbo Systems Swivel lifting eye to be used A swivel lifting eye is required to lift loads safely not supplied by ABB Swivel lifting eye Product Thread M Length L Minimum load limit loading capacity TPS44 M8 13 mm 150 kg TPS48 M10 17 mm 250 kg TPS52 ...

Page 96: ...S48 kg TPS52 kg TPS57 kg TPS61 kg 1 Filter silencer 15 19 30 40 65 2 Radial air suction branch 5 6 8 11 21 3 Axial air suction branch 3 4 4 6 9 4 Compressor casing 17 24 35 55 90 5 Wall insert 4 7 10 13 30 6 Diffuser 2 2 3 6 10 7 Cartridge group 25 35 50 85 140 8 Nozzle ring 1 1 2 3 6 9 Burst ring 1 2 3 5 12 10 Turbine casing with external burst protection 1 inlet 30 35 50 80 130 2 inlets 30 35 50...

Page 97: ...rials can lead to serious burns Do not touch hot surfaces and heed the warning plate on the turbo charger Wear heat resistant safety gloves and protective clothing Allow the turbocharger to cool down before carrying out any work Wear safety gloves to protect against thermal hazards Disconnect all air lines in accordance with the enginebuilder s instruc tions Remove the screws for the compressor ca...

Page 98: ... 8 3 Page 96 Copyright 2016 ABB All rights reserved September 2016 HZTL2412_EN Revision F Removing the insulation Loosen and remove the screws for the insulation plates 1 2 If provided Remove the insulation plates 1 2 Remove the remaining screws for the insulation 3 Remove the insulation 3 If provided ...

Page 99: ...off tool 90042 against the turbine casing To do this the two cover plates 1 2 must be removed from the hard insula tion on the turbine casing CAUTION Axial force The press off tool can generate a high axial force and if it is not used properly too much pressure on one side it can damage the rotor It should thus be used alternately on both sides while avoiding ex cessive pressure on either side Loo...

Page 100: ...d September 2016 HZTL2412_EN Revision F TPS61 wall insert removal Fasten lifting beam 90258 to wall insert Fasten swivel lifting eye a to lifting beam Remove wall insert 77000 using lifting gear Loosen screws 72041 and remove them together with lockwashers 72040 and diffuser 79000 from compressor casing 72000 Disassembly of diffuser TPS F31 32 FV31 32 ...

Page 101: ...F Installing compressor casing Refit wall insert 77000 and O ring 77005 in the reverse order NOTICE O rings Used O rings must always be replaced with new ones O rings are only available as a set see chapter Spare parts Refit diffuser in reverse order Fit compressor housing in reverse order Thoroughly clean fastening strips 72012 before fitting them Fitting the diffuser TPS F31 32 FV31 32 ...

Page 102: ...ontact with hot operating materials can lead to serious burns Do not touch hot surfaces and heed the warning plate on the turbo charger Wear heat resistant safety gloves and protective clothing Allow the turbocharger to cool down before carrying out any work Wear safety gloves to protect against thermal hazards The bearing casing is difficult to loosen Use the press off tool 90042 against the turb...

Page 103: ... nozzle ring 56001 using two extraction devices 90070 and withdraw bottom part of service support 90012 Remove C ring 51105 Mount the cartridge group on the service support 90012 and bolt it down firmly Loosen screw 42008 and remove diffuser 79000 complete with O ring 42012 Measure the axial and radial clearances see the section Axial and radial clearances If provided Disassembly of diffuser TPS F...

Page 104: ... side This can be pushed back in with a screw driver Fit the lamellar sealing ring 56005 if present in the correct slot see detail A When doing this pay attention to correct winding of the la mellar sealing ring see detail B Secure the lamellar sealing ring with adhesive tape Insert the nozzle ring 56001 with the cam facing forwards into the turbine casing as far as it will go Align the cam on the...

Page 105: ...he nozzle ring is held in place during operation it must be clamped between the partition wall and the turbine casing Calculate the press fit PD as shown NOTICE If the calculated value PD is less than 0 1 mm an official ABB Turbo charging Service Station must be contacted Measure the axial and radial clearances see the section Axial and ra dial clearances Nozzle ring press fit for single inlet tur...

Page 106: ...ts reserved September 2016 HZTL2412_EN Revision F Calculate the press fit PD as shown NOTICE If the calculated value PD is outside 0 2 mm an official ABB Turbo charging Service Station must be contacted Measure the axial and radial clearances see the section Axial and ra dial clearances Nozzle ring press fit for multiple inlet turbine cas ing ...

Page 107: ...crew 42008 Check lifting gear and fasten to bearing casing 42001 Unscrew the cartridge group and lift it out of the service support 90012 Apply high temperature grease to the centering points and screw threads Remove temporary covers from oil connections CAUTION Don t damage or shift gasket rings A in the mounting support when fitting the cartridge group The gasket rings A are supplied by the en g...

Page 108: ... casing Fasten the cartridge group using fastening strips 51002 Verbus Ripp washers 51003 and nuts 51007 also see the chapter enti tled Table of tightening torques Fasten the bearing casing 42001 using the fixing screws C Tighten the fixing screws C to the torques listed in the following table For the assembly of the turbocharger on the engine support the threads of the screws and screw heads must...

Page 109: ... and if provided fit the insulation plates 1 2 Removing gas outlet bend and gas outlet flange Disconnect all lines in accordance with engine builder s instructions and remove insulation See also preceding chapter Loop lifting gear around gas outlet bend 51100 Remove gas outlet bend 51100 and gasket 52406 Only gas outlet bends from ABB Turbo Systems have the gasket 52406 Remove gas outlet flange 52...

Page 110: ... C ring 52408 Fit the gas outlet flange 52400 In the case of gas outlet bends 51100 from ABB Turbo Systems always replace the gasket 52406 see the chapter entitled Spare parts Apply high temperature grease to contacting surfaces and threads Fit the turbine casing using the nuts 52433 while observing tightening torques specified in the table of tightening torques Fasten the insulation Attach pipes ...

Page 111: ...harp edges on the compressor wheel The compressor wheel has sharp edges which can cause injuries Wear safety gloves Wear safety gloves to protect against mechanical hazards TPS44 TPS48 TPS52 TPS57 TPS61 A minimum 0 08 0 08 0 10 0 12 0 15 A maximum 0 16 0 16 0 18 0 21 0 25 B minimum 0 51 0 50 0 61 0 72 0 81 B maximum 1 00 1 00 1 15 1 31 1 55 Permissible B clearances for standard radial bearings If ...

Page 112: ...d clockwise rotations and then compared With standard radial bearings the run out time for anticlockwise and clockwise rotating rotors is the same If one run out time is at least 1 5 times longer than the other then radial bearings with a special bearing geometry are installed The following B clearances are valid for these special bearings TPS57 TPS61 B minimum 0 46 0 52 B maximum 0 73 0 82 CAUTIO...

Page 113: ... flange The minimum and maximum values result from the manufacturing toler ances of the compressor wheel and turbine wheel or the wall insert and gas outlet flange N1 and N2 as well as R1 and R2 are each measured at the same time using two feeler gauges To measure N1 and N2 the feeler gaug es must be pushed between the wall in sert and the compressor wheel free of play in each case above and below...

Page 114: ...learance N and R Product N mm R mm TPS44 0 15 0 49 0 36 0 67 TPS48 0 22 0 58 0 47 0 77 TPS52 0 30 0 67 0 59 0 92 TPS57 0 40 0 86 0 75 1 11 TPS61 0 50 0 94 0 90 1 32 CAUTION Clearances out of tolerance Clearances out of tolerance and excessively worn components can be the cause of serious damage to machinery and property Have components assessed and if necessary replaced by an ABB Turbocharging Ser...

Page 115: ...HZTL2412_EN Revision F Table of tightening torques 8 6 The following tightening torques must be observed for the specified screw connections Position Part number TPS44 TPS48 TPS52 TPS57 TPS61 1 72020 60 60 60 60 60 2 42008 6 10 10 20 20 5 52433 20 20 40 65 65 6 51007 25 25 45 75 75 9 72011 35 35 70 105 170 10 86505 15 15 15 15 15 8 6 Tightening torques Nm ...

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Page 117: ...r 9 1 If the turbocharger is damaged and the engine can be shut down for only a short time for emergency repairs proceed as follows Fit the cover plate CAUTION Always heed precisely the engine builder s instructions in case of en gine operation with a blocked throttled turbocharger Dismantling the turbocharger Dismantle the turbocharger see the section Dismantling and fitting the turbocharger Do n...

Page 118: ...g the cover plate Close the opening in the turbine casing using the cover plate A Fasten the cover plate on the turbine casing 51000 using the fas tening strips 51002 Verbus Ripp Verbusripp washers 51003 and nuts 51007 and screw it down securely on the support NOTICE Thoroughly clean the fastening strips 51002 before fitting them Apply high temperature grease to the stud threads 51006 ...

Page 119: ...ording to the following drawing Material Common structural steel according to DIN EN 10025 2 Product B1 0 5 B2 B3 B4 0 2 B5 B6 TPS44 62 6 54 110 11 0 1 144 TPS48 65 7 60 130 11 7 1 5 150 TPS52 79 6 78 155 14 2 1 5 180 TPS57 98 2 100 190 17 2 2 220 TPS61 116 8 120 226 20 5 2 4 260 Product B7 ØD1 0 2 ØD1 0 2 ØD2 R1 M TPS44 191 3 191 3 17 88 M8 TPS48 35 7 222 7 227 7 17 105 M8 TPS52 39 6 265 7 271 7 ...

Page 120: ...9 1 Page 118 Copyright 2016 ABB All rights reserved September 2016 HZTL2412_EN Revision F Diameter for turbine casing designs for optional C ring sealing NOTICE Information about the turbine casing design with without C ring seal ing can be requested from an ABB Turbocharging Service Station ...

Page 121: ...ut of operation and this is circulated by the pre lubrication pump no measures have to be taken Any remaining old engine oil will therefore be flushed away and the bearing sections largely protected against corrosion Mothballing measures WARNING Handling operating materials and supplies Swallowing or inhaling vapours of operating materials and supplies or contact with them may be harmful to health...

Page 122: ...s are necessary after taking an engine out of operation Dismantle the turbocharger The rotor and the bearing parts must be removed by an official ABB Turbocharging service station and refitted afterwards Clean all parts Machined bright surfaces of steel and cast parts must be oiled with anticorrosive oil Reassemble complete turbocharger Rotor turning in stack draught If the rotor turns as a result...

Page 123: ...r in indi vidual parts See the section Taking out of operation for up to 12 months under Moth balling 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 i...

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Page 125: ...s made of leather Wear safety goggles Wear a respiratory mask to protect against dusts Wear safety gloves to protect against mechanical hazards Disposal must be environmentally compatible professional and in com pliance with locally applicable regulations The turbocharger consists largely of metal cast iron materials steel nickel steel alloys aluminium and bearing brass Further components are Non ...

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Page 127: ...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 cleaned and greased Dispose of replaced and unusable parts in a professional and envi ronmentally compatible way Customer spare part set 97070 The customer spare part se...

Page 128: ...l TPS44 F TPS61 F Spare parts 12 View of turbocharger showing part numbers 12 2 Page 126 Copyright 2016 ABB All rights reserved September 2016 HZTL2412_EN Revision F View of turbocharger showing part numbers 12 2 12 2 ...

Page 129: ...8 Metal C ring 56001 Nozzle ring 57200 Burst protection 57210 Burst ring 72000 Compressor casing 72011 Socket screw 72012 Fastening strips 72020 V clamp 72041 in customer spare part set Counter sunk screw with cross slotted head 77000 Wall insert 77005 in customer spare part set O ring 79000 Diffuser 81000 Filter silencer 81010 in customer spare part set O ring 82000 Axial air suction branch 82010...

Page 130: ...S44 F TPS61 F Spare parts 12 View of cartridge group showing part numbers 12 3 Page 128 Copyright 2016 ABB All rights reserved September 2016 HZTL2412_EN Revision F View of cartridge group showing part num bers 12 3 12 3 ...

Page 131: ...1002 Piston ring 25000 Compressor wheel 32101 Plain bearing bush 32103 Locking ring 32105 Thrust ring 32106 Thrust bearing 32108 Piston ring 32109 Sealing disc 32110 Bearing flange 32111 Auxiliary bearing 32112 Bearing flange 32113 Socket screw 32114 Socket screw 32221 Bearing cover 32222 O ring 42001 Bearing casing 42002 Socket screw 42008 in customer spare part set Socket screw 43001 Partition w...

Page 132: ...ABB Turbo Systems AG Bruggerstrasse 71a CH 5400 Baden Switzerland ABB ...

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