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Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33

Preliminary remarks

1

Turbocharger rating plate

1.7

Page 14

© Copyright 2016 ABB. All rights reserved.

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Turbocharger rating plate

1.7

01 Turbocharger operating limits at engine overload (110 %).

Only when operating in the test rig unless otherwise agreed with the en-

ginebuilder.

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
12    Manufacturing plant

1.7

Operating limits

Recommended replace-

ment intervals for turbo-

charger components

Further information

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Summary of Contents for HT843234

Page 1: ... Systems Ltd CH 5401 Baden Type TPL69 A32 HT843234 nMmax 420 t Mmax 650 nBmax 399 t Bmax 620 1 s C 01780 35 50 50 Year 2017 made in Switzerland Application according to the Operation Manual kg HZTL2498 English TPL69 A32 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: ... rating 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 Periodic checking of the pressure vessel 2 9 Lifting loads 3 Commissioning 3 1 Oil supply 3 2 Inspection work 3 3 Commissio...

Page 4: ... installation 7 1 Turbocharger weights 7 2 Removing 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 8 Dismantling and fitti...

Page 5: ...s reserved November 2016 HZTL2498_EN Revision B 10 2 Taking the engine 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 the turbocharger with part numbers 12 3 View of turbine cleaning system with part numbers optional ...

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Page 7: ...ied by ABB 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 o...

Page 8: ... rights reserved November 2016 HZTL2498_EN Revision B 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: ...sor wheel 12 This air then passes through the diffuser 11 and leaves the turbocharger through the com pressor 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 lubr...

Page 10: ...ght 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 third parties In addition improper use may cause damage to the machine The machine may be operated only by train...

Page 11: ...of health when handling VCIs VCI products are not hazardous in the sense of the Hazardous Sub stances Ordinance Nevertheless the following points are to be ob served when handling VCIs 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 W...

Page 12: ...by an ABB 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 N...

Page 13: ...ved This 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 fau...

Page 14: ...rts and corresponding accessories Competence of personnel The turbocharger must only be operated and serviced by trained and au thorised personnel Basic mechanical training is a prerequisite Design variants This document is valid for different design variants of turbochargers There may be sections and descriptions of components that are not rele vant for a specific turbocharger variant ABB Turboch...

Page 15: ...work on the product Definition of mandatory signs Mandatory signs show the protective equipment to be worn for a task The mandatory signs are described in chapter Safety and must be 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 Tu...

Page 16: ...e agreed with the en ginebuilder 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 12 M...

Page 17: ...commend 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 recommended replacement intervals can increase the risk of unpredictab...

Page 18: ...rights reserved November 2016 HZTL2498_EN Revision B 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 19: ...aterials 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 turbo charger by his personnel All instructions in this chapter must be obser...

Page 20: ... Ear protection 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 precise ly Warning si...

Page 21: ...ave been attached to turbochargers by ABB Turbo Sys tems 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 res...

Page 22: ...e all general 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 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 floo...

Page 23: ...ely report any damage or changes in operational perfor mance to person responsible If damage is discovered immediately shut down turbocharger and se cure 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 ...

Page 24: ...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 describ...

Page 25: ... draught 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 W...

Page 26: ...erature 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 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 turbo charger Wear heat resistant safety gloves and protective ...

Page 27: ...act with the skin Ensure good ventilation Observe details in the safety data sheets of the operating and auxil iary 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 cau...

Page 28: ...y and in an environmentally compatible manner 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 ...

Page 29: ... hazards to humans All work on or with electrical components may only be performed by trained specialists Heed any country specific regulations Periodic checking of the pressure vessel 2 8 The pressure vessels used by ABB Turbo Systems such as those for wet or dry cleaning are so called simple pressure vessels The local statutory regulations covering periodic checks of pressure vessels must be obs...

Page 30: ...et anyone stand 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 respec tive handling steps Before attaching slings allow turbocharger components to cool down...

Page 31: ...ational conditions is an important prerequisite for trouble free tur bocharger 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 speci fications for lubricating oil selection oil change intervals oil filtration oil pressure and oil temperature Oil filtration A lubricating oil filter system...

Page 32: ...tion on the turbocharger are listed below Status for operation Oil pressure in front of the turbo charger poil in bar Permissible for normal operation 1 3 2 5 Permissible during engine warm up 1 3 5 0 Temporarily admissible 1 h 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 A metering orifice is installed i...

Page 33: ...eheat the oil 30 Lubricating oil temperature at the outlet The oil temperature at the outlet is mainly dependant on Lubricating oil temperature and pressure at the oil inlet Engine load and turbocharger speed Exhaust gas temperature The maximum admissible oil temperature at the outlet is listed in the fol lowing table The specified oil outlet temperature is to be considered as alarm value for the ...

Page 34: ... 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 Check whether the warning plates are present and legible Check whether the protective sheets have ...

Page 35: ...ust gas temperature 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 ac ceptance test report while taking different operating conditions into ac count 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 a...

Page 36: ...t 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 before start up commissioning of chapter headed S...

Page 37: ...tre from 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...

Page 38: ...4 1 Page 36 Copyright 2016 ABB All rights reserved November 2016 HZTL2498_EN Revision B 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 39: ...me intervals 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 relate...

Page 40: ...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 Turbocharger speed Pressure loss in air filter Servicing work according to th...

Page 41: ...earing casing 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 assess ment of the rotor must be carried out by an ABB Turbocharging Service Station Disassemble turbocharger Measure clearances Clean the turbine and compressor...

Page 42: ...otating components 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 turbo charger compo...

Page 43: ...inlet casing 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 M...

Page 44: ...peed 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 Speed differences with multiple turbochargers per engine The speeds of all turbochargers on one engin...

Page 45: ...sure the temperatures in the air and gas lines to and from the tur bochargers 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 In any event it is recommended that you contact the nearest ABB Turbocharging Service Station Assembly If the speed sensor is not fitted on the turbochar...

Page 46: ...eed 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 and assembly NOTICE Sealing of the speed sensor The speed sensor is designed wi...

Page 47: ... 2016 ABB All rights reserved November 2016 HZTL2498_EN Revision B 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 49: ...s regular visual checks and clean ing to ensure that the turbocharger and its attached units function trouble free The external condition and how dirty the cleaning points specified in this chapter are must be established 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 F...

Page 50: ...vember 2016 HZTL2498_EN Revision B 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 51: ...e drawn in air 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 ...

Page 52: ...overings 81137 Bend sheet metal coverings 81137 back to original shape Insert the insert units E into slot guides in filter silencer unit 81135 Uniformly place cover grids 81266 in correct position Push connecting rods 81269 through lugs of cover grids 81266 CAUTION If the connecting rods 81269 are not correctly positioned in their re cesses on the filter silencer unit 81135 the cover grid 81266 c...

Page 53: ...ing screws 81272 When tightening the screws 81272 ensure that connecting rods 81269 are located correctly in recesses in filter silencer body 81135 Now tighten screws 81272 alternately until the following maximum torque is reached 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 Fit filter strip 81265 ...

Page 54: ...t oil mist or dust are in the intake air Consequences of contamination Impaired compressor efficiency Higher exhaust gas temperatures Increased fuel consumption Increased rotor unbalance Periodic cleaning of the compressor during operation prevents or delays a severe increase of the contamination It does not however replace the regular service work during which the turbocharger is completely disma...

Page 55: ...hrough an injection pipe fitted in the filter silenc er 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 provid ed 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 wat...

Page 56: ...l panel Compressor wet cleaning operation with XC2 Trigger water injection according to the specifications of the en ginebuilder The specified water pressure upstream of the connection to the turbo charger must be maintained Operate engine for at least five additional minutes after cleaning The cleaning process can be repeated up to two times How successful the cleaning was can be seen from the ch...

Page 57: ...eaning process which has been tested and is recommended by ABB Turbo Systems the following pre requisites 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 se...

Page 58: ...ected 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 Turbocharg ing Service Station ...

Page 59: ...ch is why regular and correctly performed cleaning is important in order to remove the de posits that have formed Contaminated turbine components can cause a slight increase in charging pressure because of narrowing of the turbine cross section The contami nation causes a drop in turbine efficiency and the engine temperatures downstream of the cylinder can increase The engine performance must ther...

Page 60: ... to salt water and cooling water additives Don t use salt water for cleaning but only clean fresh water 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 section Prerequisites 59 CAUTION Exhaust gas temperature stabilising and drying t...

Page 61: ...the risk of turbocharger surging is reduced We recommend finding the most suitable method by performing trials Recommended operating state for turbine wet cleaning The following operating state and prerequisites have been tested and ap proved 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 achiev...

Page 62: ...teed Open drain pipe 08 09 if provided Switch over 3 way valve 04 from scavenging air mode to water sup ply Set the required volume of water on the flowmeter as shown in the ta ble see table Cleaning parametersTPL C 3 nozzles Cleaning pa rameters for wet cleaning of turbine and nozzle ring After injecting required volume of water shut off water supply again by switching over 3 way valve 04 to scav...

Page 63: ...aning process If a drainage system is not provided the injected vol ume 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 clari fied by the operator The following must be observ...

Page 64: ...t 2016 ABB All rights reserved November 2016 HZTL2498_EN Revision B Wet cleaning parameters for turbine and nozzle ring Product Maximum tempera ture at start of cleaning process TTI C Injection time t i min Water flow rate per turbocharger with pWater 2 bar MW l min TPL65 A32 33 36 430 10 13 TPL69 A32 33 18 Table of cleaning parameters ...

Page 65: ...ensitive to mechanical damage The use of needle guns or other impact tools for example damages the components Depending on the specification nozzle rings have protec tive coatings which can also be damaged Only use soft tools such as scouring cloths brushes or wire brushes In the event of heavy contamination the cleaning methods described in this chapter such as soaking can be repeated until a sat...

Page 66: ...or the op erating materials and supplies Comply with local legislation Wear safety goggles Wear safety gloves against 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 ...

Page 67: ...ately after cleaning Remove turbocharger from the engine see chapter Removal and in stallation Remove cartridge group see chapter Disassembly and assembly First clean the compressor end and then the turbine end in accordance with the following description Cleaning the cartridge group on the compressor end CAUTION Selection of the cleaning agent Cleaning agents which contain chlorine attack metals ...

Page 68: ...ing the contamination Baked layers of contamination from fuel residue or coked oil may occur at the turbine end The contamination can be removed by soaking and brushing The procedure for soaking the layers of contamination as well as for cleaning the turbine are described in the following To soften the layers of contamination on the turbine the cartridge group can be submerged vertically in a tank...

Page 69: ...crane 2 Secure two lifting loops with swivel lifting 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 sus pend from the second crane 5 Tighten chain block until entire cartridge grou...

Page 70: ...ssor wheel The 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 t...

Page 71: ...the swivel lifting eye and attach to the first crane 5 Tighten 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 c...

Page 72: ...contamination in the cartridge group If water or contamination gets into the cartridge group the turbocharger function may be impaired and parts in the cartridge group may be dam aged 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 p...

Page 73: ...nly distributed residual contamination deposits 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 ...

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Page 75: ...tion Turbo 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 permis sible The compressor blades and turbine blades are then short ened somewhat Ce...

Page 76: ... Prolonged 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 cert...

Page 77: ...anometer Turbo 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 tur bine Clean it Damaged rotor components or bearing Contact an ABB Turbocharging Service Station Pipes Defects such as leaks i...

Page 78: ...stem Repair it or contact the manufac turer 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 ex haust 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 wa...

Page 79: ...splay wrong Replace the manometer Line to manometer leaking Repair the leak Contaminated filter silencer causing excessive loss of pres sure Clean it Compressor turbine contaminated Damaged compressor turbine Contact an ABB Turbocharging Service Station Exhaust counterpressure too high Clean or repair the boiler or ex haust silencer Charge air pressure too high Engine performance and engine speed ...

Page 80: ...oises during 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 t...

Page 81: ...hich can cause 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 at tract metal particles As a result the dis tance to the auxiliary bearing decreases which can lead to amplification of the noise component and consequen...

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Page 83: ...ion B Removal and installation Turbocharger weights 7 1 Lifting gear with a sufficient load limit must be used for removing and in stalling the turbocharger The following weight specification is the heaviest variant possible This standard value may deviate from the data on the rating plate depending on the specification TPL65 A32 A33 A36 TPL69 A32 A33 1230 1780 7 7 1 Weights kg ...

Page 84: ...ng casing When the cartridge group the bearing casing or the turbocharger is fitted to the engine it must be en sured 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 Unplug the cable connector on the speed sensor Remove the insulation at the suspension ribs TPL65 Version with compress...

Page 85: ... 02 and place a sling around the bearing casing Loosen the fixing screws at the foot Lift the turbocharger off the engine and set it down to one side WARNING Beware of tilting If support for the turbocharger is not provided or is inadequate the tur bocharger could tip over during installation or removal and cause a se rious or even fatal injury Support the turbocharger at a suitable point If possi...

Page 86: ...in the bearing casing When the cartridge group the bearing casing or the turbocharger is fitted to the engine it must be en sured 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 Adapt turbocharger to suit engine Tighten fixing screws in foot in accordance with engine builder s in stru...

Page 87: ...asing 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 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 V...

Page 88: ...quences Attach 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 ...

Page 89: ...of individual parts or assemblies are guides round ed off to the next highest value Description TPL65 A32 A33 A36 TPL69 A32 A33 01 Radial air suction branch 50 70 02 Axial air suction branch 35 03 Filter silencer 130 220 04 Compressor casing 180 260 05 Wall insert 40 65 06 Diffuser 19 35 07 Cartridge group 290 360 08 Turbine diffuser 30 50 09 Nozzle ring 10 17 10 Gas inlet casing radial 50 55 8 2 ...

Page 90: ...2016 ABB All rights reserved November 2016 HZTL2498_EN Revision B Complete compressor casing TPL65 A32 A33 A36 TPL69 A32 A33 Complete compressor casing 240 360 NOTICE The total weight of the complete compressor casing is an addition of the weights of the compressor casing the diffuser and the wall insert Weight kg ...

Page 91: ...ir lines in accordance with the engine builder s instruc tions Dismantle the insulation where necessary Pass a lifting gear around the air suction branch It is permissible to pass the lifting gear through holes possibly provided in the ribs to im prove stability Unscrew the nuts 72027 and remove them together with the washers 72018 Remove the air suction branch and set it down to one side Fit the ...

Page 92: ...served November 2016 HZTL2498_EN Revision B Remove insulation where necessary Pass lifting gear through rib on filter silencer Pass lifting gear through lugs on back Unscrew nuts 72027 and remove them together with washers 72018 Remove filter silencer and set it down to one side Install filter silencer in reverse order Removing the filter silencer Installing the filter silencer ...

Page 93: ... injury Wear safety gloves Wear safety gloves against mechanical risks The axial clearance A must be measured before removing and after fitting the cartridge group Measure and note the axial clearance A TPL65 A32 A33 A36 TPL69 A32 A33 0 31 0 49 0 33 0 50 CAUTION Clearances out of tolerance Clearances out of tolerance and excessively worn components can be the cause of serious damage to machinery a...

Page 94: ... 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 en sured 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 three studs 72029 at...

Page 95: ... together with the wall insert and diffuser and set them down with surface F on an underlay WARNING Tipping the compressor casing Make sure the underlay does not shift Allow the compressor casing to rest only on surface F Check the underlay and adjust it if necessary Remove the screws 72002 Remove the diffuser 79000 Remove the wall insert 77000 using swivel lifting eyes 90235 Remove the O ring 770...

Page 96: ...s Ripp washers 61058 Unscrew and remove two nuts 61037 Undo screw 61059 and re move together with Verbus Ripp washer 61058 Fasten separate lifting gear to each of the two ribs on the bearing cas ing provided for this purpose 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 casin...

Page 97: ...assembly 8 Removing cartridge group 8 5 Page 95 Copyright 2016 ABB All rights reserved November 2016 HZTL2498_EN Revision B Withdraw cartridge group and fit supports 90450 Remove screws 42064 flange 42044 and gasket 42045 and clean oil space Cover the oil connections ...

Page 98: ...2016 HZTL2498_EN Revision B Dismantling and installing the turbine diffuser and nozzle ring 8 6 CAUTION Falling nozzle ring The nozzle ring hangs only loosely on the positioning pins Before removing the turbine diffuser secure the nozzle to prevent it from falling Before disassembling the turbine diffuser if possible secure the nozzle ring against falling with a lashing strap and a wooden block 8 ...

Page 99: ...ge 97 Copyright 2016 ABB All rights reserved November 2016 HZTL2498_EN Revision B Position clamp 90921 over stud 61036 until it lies flat against inner radius of gas outlet casing Insert extension A of torque spanner B through clamp hole and only loosen screws 61056 one after other Do not yet remove the screws 61056 and Verbus Ripp washers 61057 ...

Page 100: ...reads 61036 Remove the remaining screws 61056 and Verbus Ripp washers 61057 Press the turbine diffuser 63000 free using the press off screws 90901 and pull it out it until the clamp 90921 is up against the nut 61037 Loop the lifting gear around the turbine diffuser 63000 and secure it to a crane Remove nuts 61037 and clamps 90921 Fully withdraw the turbine diffuser and remove it Remove the guide s...

Page 101: ...ce plates that are specified for the turbocharger have been installed in the two oil inlet channels Check correct installation of oil orifice plates Figure 2 Remove cover from oil connection Secure separate lifting gear to each of two ribs on bearing casing pro vided for this purpose Remove supports 90450 and carefully insert cartridge group Evenly tighten the three screws 61059 together with Verb...

Page 102: ...aged Turn rotor to check that blades do not rub against turbine diffuser Remove the lifting gear Screw in the speed sensor 86505 along with the O ring 86506 and plug in the cable connector 86515 Fit the O ring 77005 to the wall insert 77000 Fit the lifting gear and the swivel lifting eye 90235 Align and fit the wall insert 77000 using the centring screw 90187 Place the diffuser 79000 in position u...

Page 103: ...ts 61090 against compressor casing 72000 by tightening to specified torque See chapter Table of tight ening torques Remove lifting device 90190 Measure and note the axial clearance A see the section on axial clearance 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 ...

Page 104: ...one at the tur bine end Removing nozzle ring Remove insulation from gas inlet casing 51001 Loop rope around gas inlet casing and secure with lifting gear CAUTION When looping the securing line around the casing make sure that no cleaning pipes are squashed or damaged Do not fasten the lifting gear to cleaning pipes under any circumstances Remove two hexagon head screws 61044 together with Verbus R...

Page 105: ... down the gas inlet casing to one side use suitable under lays and take care not to damage the angles of the insulation Remove optional gasket 61050 Fitting the nozzle ring Insert optional gasket 61050 into groove in gas inlet casing 61001 Align gas inlet casing and secure using hexagon nuts 90178 on studs 90177 Insert nozzle ring 56001 and position it Brush screw threads 61044 with high temperatu...

Page 106: ...ual TPL65 A32 A33 A36 TPL69 A32 A33 Disassembly and assembly 8 Table of tightening torques 8 9 Page 104 Copyright 2016 ABB All rights reserved November 2016 HZTL2498_EN Revision B Table of tightening torques 8 9 8 9 ...

Page 107: ...8_EN Revision B Position Part number TPL65 A32 A33 A36 TPL69 A32 A33 01 82005 M16x1 5 45 M16x1 5 45 04 72027 with washer M14 95 M16 125 05 72029 M14 30 M16 30 06 61044 61059 61071 TPL69 A32 33 M14 160 M16 260 61056 M14 150 M16 260 07 61036 M12 80 M16 105 10 61037 M14 75 M16 105 11 61090 M14 5 M16 10 14 86505 M18x1 5 150 M18x1 5 150 103 72002 M10 50 M12 80 Tightening torques Nm ...

Page 108: ......

Page 109: ... the alarm and depending on the situation stop the engine Seal the oil leak 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...

Page 110: ...chargers This 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 lubricat ing oil system must remain connected to this turbocharger also and be turned on if the gas inlet cannot be blocked See section Further me...

Page 111: ...sor wheel Position screws 94007 in unoccupied threaded holes of compressor wheel and tighten them as specified in following Table of tightening torques CAUTION Do not remove any balancing screws from compressor wheel Use only unoccupied threaded holes to fit lifting spigot Position assembly disassembly device 90020 over studs 72026 and locking flange 94003 Turn compressor wheel so that locking fla...

Page 112: ...t short notice 9 Locking the rotor 9 2 Page 110 Copyright 2016 ABB All rights reserved November 2016 HZTL2498_EN Revision B Part number TPL65 A32 A33 A36 72027 M14 75 Nm 94007 M8 25 Nm CAUTION Make sure all components are clean and free from grease Table of tightening torques ...

Page 113: ...003 into compressor wheel Position screws 94007 in unused threaded holes of compressor wheel and tighten them as specified in the following Table of tightening torques CAUTION Don t remove any balancing screws from compressor wheel Use only unoccupied threaded holes to fit lifting device Push intermediate ring 94001 and assembly disassembly device 90020 onto locking flange 94003 in correct order A...

Page 114: ...All rights reserved November 2016 HZTL2498_EN Revision B Tighten nuts 74027 complete with washers 72018 on compressor casing as specified in following Table of tightening torques Part number TPL69 A32 A33 72027 M16 105 Nm 94006 M6 10 Nm 94007 M6 10 Nm CAUTION Make sure all components are clean and free from grease Table of tightening torques ...

Page 115: ...be removed 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 ...

Page 116: ...te 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 TPL65 13 325 30 30 8 10 6 70 TPL69 13 385 30 30 8 10 6 84 Product Ø 1 Ø 2 Ø 3 Ø 4 Ø 5 Ø 6 TPL65 616 694 660 16 22 15 TPL69 726 818 779 18 25 15 Product α 1 α 2 α 3 TPL65 TPL69 4 x 90 37 5 24 x 15 9 3 Cover plate dim...

Page 117: ...A33 Taking out of operation at short notice 9 Fit cover plate 9 3 Page 115 Copyright 2016 ABB All rights reserved November 2016 HZTL2498_EN Revision B NOTICE Carry out the work as described in the chapter Removal and fitting Remove cartridge group ...

Page 118: ...ce 9 Fit cover plate 9 3 Page 116 Copyright 2016 ABB All rights reserved November 2016 HZTL2498_EN Revision B 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 119: ...he engine builder s instructions 4 stroke engine with several turbochargers No further measures are necessary on engines with separate air and ex haust 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 e...

Page 120: ... to the turbocharger 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...

Page 121: ... replaced by preserving oil before taking the engine out 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 ...

Page 122: ...measures are necessary after taking an engine out of opera tion 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 ...

Page 123: ... whole or 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 turboc...

Page 124: ......

Page 125: ...work gloves made 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 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...

Page 126: ......

Page 127: ...T Description 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 ...

Page 128: ...bus Ripp washer 42058 2 Hexagon head screw 42059 3 Hexagon nut 61037 12 Hexagon head screw 61056 12 Verbus Ripp washer 61057 3 Verbus Ripp washer 61058 3 Hexagon head screw 61059 1 Gasket 77005 1 O ring speed sensor 86506 Quantity Description Part number 1 O ring 42012 1 Gasket 42041 2 Gasket 42045 15 Verbus Ripp washer 42058 42063 61043 61057 61058 15 Hexagon head screw 42059 42064 61044 61056 61...

Page 129: ...turbine cleaning system if provided CAUTION Leaks Improper assembly of the cleaning pipe and the nozzles can lead to leaks and failure of the turbine cleaning system Work on turbine cleaning system should be carried out only by an ABB Turbocharging service station Quantity Description Part number 2 Locking plate 51255 3 Nozzle 52208 6 Sleeve 52212 1 Locking plate 52213 6 Strain bolt 52217 6 Nut 52...

Page 130: ...32 A33 A36 TPL69 A32 A33 Spare parts 12 View of the turbocharger with part numbers 12 2 Page 128 Copyright 2016 ABB All rights reserved November 2016 HZTL2498_EN Revision B View of the turbocharger with part numbers 12 2 12 2 ...

Page 131: ...nut 61043 in customer spare part set Verbus Ripp Washer 61044 in customer spare part set Hexagon head screw 61050 only TPL65 A32 A33 Spiral gasket 61056 in customer spare part set Hexagon head screw 61057 in customer spare part set Verbus Ripp Washer 61058 in customer spare part set Verbus Ripp Washer 61059 in customer spare part set Hexagon head screw 63000 Turbine diffuser 68000 Foot 72000 Compr...

Page 132: ...November 2016 HZTL2498_EN Revision B View of turbine cleaning system with part numbers optional 12 3 Part number Description 51229 Cleaning pipe 52249 Holder complete 51255 in spare parts set Locking plate 52208 in spare parts set Nozzle 52212 in spare parts set Bush 52213 in spare parts set Locking plate 52217 in spare parts set Strain bolt 52218 in spare parts set Nut 12 3 ...

Page 133: ...ABB Turbo Systems AG Bruggerstrasse 71a CH 5400 Baden Switzerland ABB ...

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