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Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30

5 Maintenance / 5.1 Foreword to Maintenance

© Copyright 2018 . All rights reserved.

HZTL2481_EN

Revision C

May 2018

5 Maintenance

5.1 Foreword to Maintenance

Maintenance and servicing work involves 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 spe-
cified intervals.

¡

The safety precautions must be observed during all maintenance and
servicing work.

The cleaning points described in the following are:

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Filter silencer

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Compressor

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Turbine and nozzle ring

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Summary of Contents for HT843754

Page 1: ...bo Systems Ltd CH 5401 Baden Type TPL73 A32 HT843754 nMmax 366 t Mmax 650 nBmax 344 t Bmax 620 1 s C 0 35 50 50 Year 2018 made in Switzerland Application according to the Operation Manual kg HZTL2481 English TPL73 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: ...ns 15 2 5 Warning plates on the turbocharger 16 2 6 Safe operation and maintenance 17 2 7 Hazards during operation and maintenance 20 2 8 Periodic checking of the pressure vessel 25 2 9 Lifting loads 25 3 Start up 27 3 1 Oil supply 27 3 2 Inspection work 30 3 3 Commissioning after taking out of operation 32 4 Operation 33 4 1 Noise emissions 33 4 2 Servicing work 35 4 3 Replacement intervals for t...

Page 4: ...Removing cartridge group 89 8 6 Dismantling and installing the turbine diffuser and nozzle ring 96 8 7 Installing cartridge group 100 8 8 Dismantling and fitting nozzle ring at turbine end 107 8 9 Table of tightening torques 114 9 Taking out of operation at short notice 116 9 1 Possibilities for emergency repair 116 9 2 Locking the rotor 117 9 3 Fit cover plate 122 9 4 Blocking the inlets and outl...

Page 5: ...urbo Systems and to use it as intended It provides important information in order that the turbocharger can be operated safely correctly and efficiently This Operation Manual complements and expands existing national reg ulations concerning work safety and accident prevention Target group This Operation Manual is intended for engineers and qualified mechan ics who are responsible for operating the...

Page 6: ...ights reserved HZTL2481_EN Revision C May 2018 1 2 Layout and function 01Filter silencer 08Nozzle ring 02Radial plain bearing 09Turbine wheel 03Thrust bearing 10Bearing casing 04Bearing bush 11Diffuser 05Radial plain bearing 12Compressor wheel 06Gas outlet casing 13Compressor casing 07Gas inlet casing Page 4 136 ...

Page 7: ...2 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 lubricating oil...

Page 8: ...er accepts no li ability for other applications If it is used otherwise ABB Turbo Systems reserves the right to reject all warranty claims State of the art 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 th...

Page 9: ...VCI products are not hazardous in the sense of the Hazardous Sub stances Ordinance Nevertheless the following points are to be ob served when handling VCIs u Ensure good room ventilation u Do not eat drink or keep food at the workplace while working with VCIs u Wear safety gloves u Clean hands and face after working with VCIs u For further information refer to www branopac com Wear safety gloves t...

Page 10: ...arging Service Sta tion and repacked u Inspect the package for damage If the package is damaged the tur bocharger or cartridge group must be inspected by an ABB Tur bocharging 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 Replacem...

Page 11: ...sion and wearing of personal protective equipment NOTICE The manner in which personnel work on and with the turbocharger with regard to safety and risks is to be checked on a regular basis in accord ance with the Operation Manual u The turbocharger must be shut down immediately in the event of modifications affecting safety or of corresponding operating beha viour by stopping the engine The fault ...

Page 12: ...mpetence 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 rel evant for a specific turbocharger variant ABB Turbocharging Service Stations will be happ...

Page 13: ... product Definition of mandatory signs Mandatory signs show the protective equipment to be worn for a task The mandatory signs are described in chapter Safety and must be com plied 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 System...

Page 14: ...wise agreed with the enginebuilder 02 Turbocharger operating limits during operation Recommended replace ment intervals for tur bocharger components 03 Replacement interval for plain bearings in 1000 h 04 Replacement interval for compressor in 1000 h 05 Replacement interval for turbine in 1000 h Further information 06 Part number for customer 07 Designation of special design 08 Turbocharger weight...

Page 15: ...ing at overload 110 during trials on the engine test bed These limits can also be permitted during op eration for special applications Operation above nMmax and tMmax is not per mitted Non observance of the recommended replacement intervals can increase the risk of unpredictable component failures 1 7 2 Positions of the rating plates A rating plate is attached to the turbocharger foot one on the l...

Page 16: ...equence of insufficient observance of the safety instruc tions are the consequence of unsatisfactory and improper execution of maintenance and inspection work The operating company is responsible for access to the turbocharger as well as the organisational measures that regulate the safe handling of the turbocharger by its personnel All instructions contained in this chapter must be observed for s...

Page 17: ...et Ear protection 2 4 Definition of Safety instructions The following symbols and terms used in this manual concern safety or refer to possible hazards WARNING Definition of warning Serious personal injuries 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 pre cisely u Warnin...

Page 18: ...arning plates that must be observed are attached to the turbocharger The warning plates must always be present in the intended locations and must be legible Part number Size mm Product 81080 105 x 74 TPL TPR When uninsulated turbochargers are delivered to the engine builder the warning plates must be subsequently attached to the insulation This is the responsibility of the engine builder Page 16 1...

Page 19: ...on the turbocharger if you are under physical or mental stress u Work only with suitable tools as well as equipment and working ma terials that are in perfect condition u Electric tools must be solidly earthed and connecting cables may not be damaged u Keep the workplace clean clear away loose objects and remove obstacles on the floor u Keep the floor equipment and the turbocharger clean u Have oi...

Page 20: ...ny damage or changes in operational perform ance to person responsible u If damage is discovered immediately shut down turbocharger and se cure it against inadvertent or unauthorized use u 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 If cleaning agents or solven...

Page 21: ...e that the supply of oil is interrupted especially with an external oil supply u 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 u Perform only those tasks that are described in this manual u Perform work only for which training has been carried out Safety ...

Page 22: ... turbocharger in accordance with instructions u 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 instruc tions due to inadequate care or as a consequence of insufficient train ing WARNING Mechanica...

Page 23: ...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 operating materials lubricating oil become hot The surface temperat ure is dependent on the effectiveness of the insulation being used The temperature can become high enough so that it falls into ranges where burns are possible...

Page 24: ...urbocharger surfaces is compuls ory Wear safety gloves to protect against thermal hazards Hazards due to operating and auxiliary materials Operating and auxiliary materials are substances used for operation or the execution of maintenance work Oils greases coolants cleaning agents and solvents acids etc can be regarded as hazardous materials Operating and auxiliary materials can be combustible and...

Page 25: ...r contamination of the ground and water due to improper disposal can lead to environmental damage u Handle operating and auxiliary materials carefully u Heed the instructions for use safety data sheets and hazard notices on the containers of the operating and auxiliary materials u Wear appropriate protective clothing u Avoid inhalation and contact with the skin u Ensure that the work space is adeq...

Page 26: ...work area u Take particular care when removing old insulating materials u Dispose of insulating materials properly and in an environmentally compatible way in accordance with applicable local regulations Wear safety goggles Wear a respiratory mask to protect against dusts Wear safety gloves to protect against chemical hazards u Use only suitable non combustible insulating materials u Ensure that t...

Page 27: ...vessels must be observed The operating company is responsible for the safe operation of the pressure vessel WARNING Danger due to pressure vessels The operating company must make sure the pressure vessels are in proper working condition and monitor them Necessary repair or main tenance work must be carried out without delay and the required safety precautions must be taken u Pressure equipment mus...

Page 28: ...nsile loading u Fasten turbocharger assemblies components as described in re spective handling steps u Before attaching slings allow turbocharger components to cool down maximum 80 C u Use suitable protection at sharp edges u Completely screw in assembly fitting devices without fail so that they cannot work loose during use u Use assembly fitting devices only for applications described u Make sure...

Page 29: ...ons is an important prerequisite for trouble free turbocharger operation The turbocharger is normally lubricated with oil from the engine oil cir cuit NOTICE With regard to the oil supply please observe the engine builder s spe cifications for lubricating oil selection oil change intervals oil filtration oil pressure and oil temperature Oil filtration A lubrication oil filter system with a filter ...

Page 30: ... turbocharger are listed below Status for operation Oil pressure at measuring point M poil in bar Permissible for normal operation 1 3 2 5 Permissible during engine warm up 1 3 5 0 Temporarily admissible 1 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 Oil orifice A metering orifice is installed in the oil inlet of the turb...

Page 31: ...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 turbocharger oper...

Page 32: ... Contaminated oil Particles of dirt and solid matter in the oil can cause serious damage to the machine or property u During initial commissioning and after all service work the complete lubricating system must be flushed thoroughly with warm oil u When running in the engine and after all service work on the lubricat ing system special running in filters must be used u Check oil pressure in oil su...

Page 33: ...gas temperature in front of and behind turbine u Measure air temperature in front of and behind compressor The measured values must be compared with the values in the accept ance test report while taking different operating conditions into ac count NOTICE Lubricants and pastes used during assembly of the turbocharger li quefy or vaporise and might escape as an oily liquid in the first few hours af...

Page 34: ... duct before gas inlet and after gas outlet u Inspect exhaust gas duct line in front of and after turbine for any combustion deposits foreign matter or residual water Clean and re move u Inspect air supply line or filter silencer for any foreign matter Clean and remove u Start up turbocharger oil circulation system at engine end u Prepare turbocharger for operation as instructed in section Inspec ...

Page 35: ...e 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 or der 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 acoustic ...

Page 36: ...ions Copyright 2018 All rights reserved HZTL2481_EN Revision C May 2018 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 34 136 ...

Page 37: ...N Shortened service intervals Despite observance of the service intervals unusual loads such as sev eral start stops a day harsh environmental factors poor fuel quality or heavy installation vibration can lead to premature machine damage u A shortened service interval must be arranged with ABB Turbo Sys tems NOTICE Service inspection after 5 years To prevent age and stoppage related machine damage...

Page 38: ...anufacturer 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 If provided Air temperature behind compressor and charge air cooler Turbocharger speed Pressure loss in air filter 4 2 3 Servicing work according...

Page 39: ... blow air through oil ports u Clean nozzle ring and check for cracks and erosion u Inspect and assess bearing parts and rotor 4 2 5 Service work every 24000 36000 hours The replacement of bearing parts and the inspection and assessment of the rotor must be carried out by an ABB Turbocharging Service Station u Disassemble turbocharger u Clearance measurement u Clean the turbine and compressor wheel...

Page 40: ...lacement intervals for non rotating 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 Influencing parameters The following parameters influenc...

Page 41: ...t GAS MDO HFO Gas 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 Recommended replace ment intervals h Rotor component...

Page 42: ...not use cables as a climbing aid If you pull the speed measurement cables too hard contacts can be pulled out u Do not tension the speed measurement cables Part number Description 42047 Screw plug 86505 Speed sensor 86515 Cable connector for 86505 86526 F I converter 86528 Tachometer 4 4 1 Speed differences with multiple turbochargers per engine The speeds of all turbochargers on one engine differ...

Page 43: ...s 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 u Inspect the air and gas lines as well as the turbocharger and eliminate any problems u In any event it is recommended that you contact the nearest ABB Tur bocharging Service Station 4 4 2 Assembly If the speed sensor is not fitted on the turbocharger the f...

Page 44: ...hen stop the engine u Switch off the lubricating oil supply to the turbocharger u Disconnect the cable connector from the speed sensor u Screw out defective speed sensor u Screw in a new speed sensor to the stop u 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 with a ...

Page 45: ...ter silencer can cause a loss of pres sure A significant pressure loss indicates an increase in dirt build up in the filter material 4 5 1 U tube manometer on filter silencer if present 81000 Filter silencer 81050 U tube manometer A mm H2O Pressure loss Pressure difference With a clean filter silencer and clean filter mat if provided the max imum pressure loss A is 120 mm H2O at full load When the...

Page 46: ...All rights reserved HZTL2481_EN Revision C May 2018 4 6 Stopping the engine CAUTION Stopping the engine Heat in the turbocharger must be dissipated by the further circulating lubricating oil u Allow the engine to continue running at idling speed for a further 10 minutes before stopping Page 44 136 ...

Page 47: ...ual 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 spe cified intervals The safety precautions must be observed during all maintenance and servicing work The cleaning points described in the following are Filter silenc...

Page 48: ...EN Revision C May 2018 5 2 Cleaning the filter silencer 5 2 1 Filter silencer with tension band 81265Filter ring if provided 81266Cover grid 81270Tension band 81136Absorption segment 81271Lock 81137Sheet metal covering 81268Connecting strip 81135Filter silencer body EInsert unit absorption segment sheet metal covering fitted Page 46 136 ...

Page 49: ...nits E bend open sheet metal coverings 81137 then take out absorption segments 81136 u Clean the absorption segments 81136 During cleaning ensure that the absorption segments 81136 are only cleaned with a mild jet of compressed air soft brush or a damp cloth Otherwise there is a risk of damage or deformation NOTICE Replace heavily contaminated absorption segments filter ring and damaged connecting...

Page 50: ...rved HZTL2481_EN Revision C May 2018 5 2 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 sheetmetal covering Page 48 136 ...

Page 51: ...in air is Clean filter strip every 500 hours of service or more frequently if necessary u Unscrew and remove lock nuts 81273 u Unscrew and remove screws 81272 for connecting rods 81269 u Remove connecting rods 81269 u Carefully remove cover grids 81266 u Pull out insert units E bend open sheet metal coverings 81137 and then remove absorption segments 81136 u Clean the absorption segments 81136 Dur...

Page 52: ...hrough the lugs of cover grids 81266 CAUTION If connecting rods 81269 are not correctly positioned in their recesses on filter silencer body 81135 cover grid 81266 can twist and shift There is then a risk of foreign matter and contamination getting into the compressor u Join connecting rods 81269 using screws 81272 When tightening the screws 81272 ensure that connecting rods 81269 are located corr...

Page 53: ... flow channels if salt oil mist exhaust gas or dust are sucked in with the 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 any major increase in contamination It does not however replace the regular service work during which t...

Page 54: ...el through an injection pipe fitted in the fil ter silencer or the suction branch The water does not act as a solvent but the contamination deposit is re moved by the mechanical impact of the droplets This is a very suitable process provided that the degree of contamination is not too high CAUTION Corrosion and deposits when cleaning Damage and impairment of turbocharger parts due to salt water an...

Page 55: ...ater injection according to the specifications of the en ginebuilder u The specified water pressure upstream of the connection to the tur bocharger must be maintained u Operate engine for at least five additional minutes after cleaning Not more than three cleaning cycles should be conducted consecutively Cleaning parameters for XC2 for each turbocharger compressor Product Engine load Water pres su...

Page 56: ...h has been tested and is recommended by ABB Turbo Systems the following pre requisites must be fulfilled ü Engine load 50 85 u Start of cleaning cycle in accordance with following description for wet cleaning operation with XC3 Operating procedure for compressor wet cleaning with XC3 Operating the water pres sure vessel u The operating state prerequisites for compressor cleaning with XC3 must be f...

Page 57: ... least 5 minutes to allow turbocharger to dry NOTICE If the cleaning operation is not satisfactory it may be repeated up to two times If the cleaning result is 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 Turbochar ging Service Station Cleaning parameters per turbocharg...

Page 58: ...ses a drop in turbine efficiency and the engine tem peratures downstream of the cylinder can increase The engine perform ance must therefore be reduced if necessary The contamination of the turbine also causes rotor unbalance Extremely heavy contamination can lead to non permissibly high unbalance of the rotor Operating experience has shown that in spite of regular cleaning during operation it is ...

Page 59: ...e 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 PrerequisitesTPL A C Operating state prerequisites for wet cleaning turbine and nozzle ring 58 CAUTION Reduced service life of the components Failure to comply with the minimum stabilisation time before cleaning the prescribed turbine inl...

Page 60: ...lowing operating state and prerequisites have been tested and approved by ABB Turbo Systems for the cleaning process u The engine has just been started or the engine load has been reduced as far as possible best cleaning is achieved at a load level of roughly 10 15 u As soon as the turbine inlet temperature is stable and below 430 C wait at least another 10 minutes for the charger parts to cool do...

Page 61: ...ode to water sup ply u Set the required volume of water on the flowmeter as shown in the table see table Cleaning parameters u Shut off the water supply again by switching the 3 way valve 04 to scavenging air mode after injecting the required volume of water u The injection process has been completed u Close drain hole if provided above drain pipe 08 09 u After cleaning wait with engine running fo...

Page 62: ...ded the in jected volume of water can be controlled by a flowmeter in the water supply The maximum volume of water allowed in individual cases must be determined together with an ABB Turbocharging Service Station The influence of the cleaning water on peripheral equipment such as a boiler must be clarified by the operator Points to remember when cleaning The following points must be observed with ...

Page 63: ... All rights reserved HZTL2481_EN Revision C May 2018 Wet cleaning parameters for turbine and nozzle ring Table of cleaning para meters Product Maximum tem perature at start of cleaning pro cess TTI C Injection time t i min Water flow rate per tur bocharger at pWater 2 bar MW l min TPL69 A 430 10 18 TPL73 A 24 TPL77 A 37 Page 61 136 ...

Page 64: ...are sensitive to mechanical damage The use of needle guns or other impact tools for example damages the components Depending on the specification nozzle rings have pro tective coatings which can also be damaged u Only use soft tools such as scouring cloths brushes or wire brushes u In the event of heavy contamination the cleaning methods de scribed in this chapter such as soaking can be repeated u...

Page 65: ...ty goggles Wear safety gloves to protect against chemical hazards Wear a respiratory mask to protect against gases Baked on layers of contamination for example from heavy fuel oil or coked oil occur at the turbine end The following performance relevant parts can be cleaned according to the following description 56001 Nozzle ring 63000 Turbine diffuser u Place contaminated parts in hot water or in ...

Page 66: ...contain chlorine attack metals u Use only pH neutral cleaning agents which do not attack metals u Observe safety data sheet CAUTION Water and contamination in the cartridge group If water or contamination penetrates the cartridge group this can im pair the function of the turbocharger and damage parts inside the cart ridge group u Make sure that no water or contamination can enter into the cart ri...

Page 67: ...The cartridge group must be rotated to do this u Two cranes or chain blocks must be used for the rotating operation Suspending the chain block directly from the crane and rotating the cart ridge group is not permitted because of the risk of damage to the com pressor wheel Cartridge group with one central suspension point CAUTION Damage to compressor wheel The lifting gear must not touch the compre...

Page 68: ...served HZTL2481_EN Revision C May 2018 4 When the cartridge group is horizontal secure one chain block to one of the upper push off threads using a swivel lifting eye and suspend from the second crane 5 Tighten chain block until entire cartridge group is suspended from second crane 6 Remove loop from first crane Page 66 136 ...

Page 69: ...ting gear must not touch the compressor wheel at any time dur ing rotation u Choose appropriate lifting gear length 1 Suspend cartridge group from the two side suspension points on the crane using two lifting loops or Attach two swivel lifting eyes to the side and suspend the cartridge group from the crane using two lifting loops 2 Attach third lifting loop with swivel lifting eye to thread of oil...

Page 70: ...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 u Use only pH neutral cleaning agents which do not attack metals u Observe safety data sheet u Fill the tank with soaking liquid u Only immerse the cartridge group until all blades are covered with cleaning age...

Page 71: ...ger function may be impaired and parts in the cartridge group may be damaged u Place cartridge group on suitable wooden or metal supports u Allow the layers of contamination on the turbine to soak for at least four hours Removing contamination WARNING Health hazard due to soot particles If soot particles enter the eyes or respiratory tract this can be harmful to health u Avoid the formation of dus...

Page 72: ...rotor unbalance This can result in bearing or turbocharger damage u Remove all traces of contamination from the turbine u After brushing off the contamination fill the tank with clean water not salt water u Submerge the turbine of the cartridge group in clean water so that loose particles of contamination detach completely u Lift the cartridge group u Dry turbine and gap between turbine and sealin...

Page 73: ...r ger Rotor unbalance Contact an ABB Turbocharging Service Station Damaged turbine or com pressor Damaged bearing Rubbing of rotating parts Normal behaviour no malfunction Turbochar ger Minor uniform wear around the periphery of rotor components caused by slight local rubbing of adjacent components is per missible The compressor blades and turbine blades are then shortened somewhat Certain toleran...

Page 74: ...iodic surging Possible damage to components such as the compressor wheel tur bine blades bearings and filter silencer u Have the cause clarified immediately by an ABB Turbocharging ser vice station and rectified u Have components inspected for damage and if necessary replaced by an ABB Turbocharging service station Sporadic surge blows Surging of the turbocharger can occur during certain operating...

Page 75: ...char ger 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 Turbochar ger 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 ex haust ...

Page 76: ... starvation for example filter silencer clogged with dirt Clean it Compressor turbine con taminated Exhaust counterpressure too high Clean or repair the boiler or ex haust silencer Enlarged flow cross section of the nozzle ring due to de formed blade trailing edges Contact an ABB Turbocharging Service Station Damaged or eroded turbine Charge air cooler Cooler contaminated Clean it Cooling water vo...

Page 77: ...e the manometer Line to manometer leaking Repair the leak Contaminated filter silencer causing excessive loss of pres sure Clean it Compressor turbine contam inated Damaged compressor tur bine Contact an ABB Turbocharging Service Station Exhaust counterpressure too high Clean or repair the boiler or ex haust silencer Charge air pressure too high Engine performance and engine speed unchanged air in...

Page 78: ...un down Possible causes Elimination Turbochar ger 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 Turbochar ger Turbocharger contaminated Clean it Damaged bearing Contact an ABB Turbocharging Service Station Rubbing rotor Foreign object in turbocharger Pa...

Page 79: ... prob lems for the evaluation electronics This problem is eliminated by removing the gasket Defective sensor Contact ABB Turbocharging service sta tion Measured speeds too high Dirty sensor tip The sensor tip is 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 consequently to fault...

Page 80: ...val and installation 7 1 Turbocharger weights Lifting gear with a sufficient load limit must be used for removing and installing 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 Weights kg TPL69 A TPL73 A TPL77 A 1780 3070 4840 Page 78 136 ...

Page 81: ...two oil inlet channels in the bearing casing When the cartridge group the bearing casing or the turbocharger is fitted to the engine it must be ensured that the orifice plates that are specified for the turbocharger have been installed in the two oil inlet channels u Check correct installation of oil orifice plates u Unplug the cable connector on the speed sensor u Remove the insulation at the sus...

Page 82: ...d the bearing casing u Attach one lifting gear each to the two fins of the bearing casing provided for this purpose u Loosen the fixing screws at the foot u Lift the turbocharger off the engine and set it down to one side WARNING If support for the turbocharger is missing or defective the turbochar ger can tip over during installation and removal and cause serious injur ies or even fatal accidents...

Page 83: ... casing When the cartridge group the bearing casing or the turbocharger is fitted to the engine it must be ensured that the orifice plates that are specified for the turbocharger have been installed in the two oil inlet channels u Check correct installation of oil orifice plates u Adapt turbocharger to suit engine u Tighten fixing screws at foot in accordance with engine builder s in structions u ...

Page 84: ...scribed in this chapter u Mark the casing position for assembly 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 u Visually check for corrosion cracks deformation and wear u Don t use...

Page 85: ...ochargers assemblies or individual components only to lifting gear which is in technically perfect condition and has suffi cient load capacity u Make sure the load is suspended properly on the crane hook u Do not let anyone stand beneath a suspended load Wear safety gloves to protect against mechanical hazards Wear safety helmet Definition of terms Suspension point Defined load attachment point on...

Page 86: ...s roun ded off to the next highest value Assemblies Weights kg Description TPL69 A TPL73 A TPL77 A 01 Radial air suction branch 80 140 160 02 Filter silencer 140 250 410 03 Compressor casing internal part 85 150 260 04 Wall insert 85 140 280 05 Diffuser 40 60 80 06 Compressor casing external part 180 290 480 07 Cartridge group 360 550 950 08 Turbine diffuser 50 75 150 09 Nozzle ring 17 25 45 10 Ga...

Page 87: ...rights reserved HZTL2481_EN Revision C May 2018 Complete compressor casing internal part Weights kg TPL69 A TPL73 A TPL77 A 210 350 620 NOTICE The total weight of the complete internal part of the compressor casing includes the internal part of the compressor casing the diffuser and the wall insert Page 85 136 ...

Page 88: ...ction branch u Disconnect all air lines ducts in accordance with engine builder s in structions u Remove insulation where necessary u Loop lifting gear around air suction branch Pass lifting gear through possibly provided holes in ribs to improve stability u Unscrew nuts 74027 and remove together with washers 74018 u Remove air suction branch and set down to one side Install air suction branch u I...

Page 89: ... Removing filter silencer u Remove insulation where necessary u Fit swivel lifting eye 90231 to filter silencer Or u Pass lifting gear through rib on filter silencer u Pass lifting gear through lugs at back u Unscrew nuts 74027 and remove them together with their washers 74018 u Remove filter silencer and set down to one side Fitting filter silencer u Fit filter silencer in reverse order Page 87 1...

Page 90: ...t mechanical hazards u Screw on at least four nuts 74027 together with washers 74018 equally spaced around the circumference and tighten them to secure the partition wall axially u Measure and note the axial clearance A Axial clearance TPL69 A TPL73 A TPL77 A Clearance A mm 0 33 0 50 0 36 0 53 0 39 0 57 CAUTION Clearances out of tolerance Clearances out of tolerance and excessively worn components...

Page 91: ...th washers 74018 equally spaced around circumference and tighten u Remove insulation If provided u Take nuts 90458 out of toolbox and screw onto threaded studs of safety segments 76080 on compressor casing internal part 76000 u Tighten nuts 90458 to specified torque see Table of tightening torques Tightening torque for nut 90458 TPL69 A TPL73 A TPL77 A 20 Nm 30 Nm NOTICE Note the control dimension...

Page 92: ...wo holes free for lifting device 90190 u Using press off screws 90900 press off the compressor casing in ternal part 76000 until the lifting device 90190 with shackle 90195 can be attached and secured to the crane u Slightly lift compressor casing internal part complete with wall insert and diffuser remove guide studs 90320 and then withdraw u Fit support angle 90025 u Set down compressor casing i...

Page 93: ...on C May 2018 u Loop the lifting device around the rear of the flange F u Carefully rotate the compressor casing internal part with wall insert and diffuser over the support bracket 90025 and set it down with the front side of the flange F on the underlay CAUTION Make sure that underlay does not shift u Check underlay and adjust if necessary Page 91 136 ...

Page 94: ... 2018 All rights reserved HZTL2481_EN Revision C May 2018 u Remove screws 76002 u Loop lifting gear around diffuser 79000 and remove diffuser u Carefully press off the wall insert 77000 using the press off screws 90900 and remove it using the swivel lifting eye 90230 u Remove O rings 77005 and 77006 Page 92 136 ...

Page 95: ... reserved HZTL2481_EN Revision C May 2018 u Fasten the lifting device 90190 with shackle 90195 to the com pressor casing external part 74000 and secure it to the crane u Loosen nuts 61037 u Uniformly press off compressor casing external part 74000 using three press off nuts 61090 remove it and set down to one side Page 93 136 ...

Page 96: ...d the flange CAUTION Oil orifice plates An orifice plate for adjusting the oil pressure is fitted in each of the two oil inlet channels in the bearing casing When the cartridge group the bearing casing or the turbocharger is fitted to the engine it must be ensured that the orifice plates that are specified for the turbocharger have been installed in the two oil inlet channels u Check correct insta...

Page 97: ...aring casing provided for this purpose u Evenly press off cartridge group by screwing press off screws 90900 into the designated holes CAUTION If the blades on the rotor have insufficient or no clearance this might cause damage to the blades and the casing u Check that the blades do not rub on the turbine diffuser by rotating the rotor u Withdraw cartridge group and fit supports 90450 u Remove scr...

Page 98: ... C May 2018 8 6 Dismantling and installing the turbine diffuser and nozzle ring CAUTION Falling nozzle ring The nozzle ring hangs only loosely on the positioning pins u Before removing the turbine diffuser secure the nozzle to prevent it from falling u Before disassembling the turbine diffuser if possible secure the nozzle ring against falling with a lashing strap and a wooden block Page 96 136 ...

Page 99: ...ght 2018 All rights reserved HZTL2481_EN Revision C May 2018 u Position clamp 90921 over stud 61036 until it lies flat against inner radius of gas outlet casing u Insert extension A of torque spanner B through hole in clamp and loosen screws 61056 61057 one after other u Do not yet remove the screws 61056 and Verbus Ripp washers 61057 Page 97 136 ...

Page 100: ...ide studs 90320 and studs 61036 u To secure the work screw the nuts 61037 onto the start of stud threads 61036 u Remove the remaining screws 61056 and Verbus Ripp washers 61057 u 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 u Loop the lifting gear around the turbine diffuser 63000 and secure it to a cran...

Page 101: ...018 u Fasten the holder 90490 to the gas outlet casing u Pull the nozzle ring 56001 in the forward direction fasten it to the lifting gear and remove it Installing the turbine diffuser and nozzle ring u Install the nozzle ring and turbine diffuser in the reverse order of re moval u Coat the screw threads with high temperature grease u Align nozzle ring with holes or cams in gas inlet casing Page 9...

Page 102: ...e bearing casing or the turbocharger is fitted to the engine it must be ensured that the orifice plates that are specified for the turbocharger have been installed in the two oil inlet channels u Check correct installation of oil orifice plates u Remove the cover from the oil connection u Fit flange 42044 with screws 42064 and new gasket 42045 u Attach one lifting gear each to the two fins of the ...

Page 103: ...s ing could be damaged u Check that the blades do not rub on the turbine diffuser by rotating the rotor u Remove the lifting gear u Fit O ring 42012 u Screw in the speed sensor 86505 together with the O ring 86506 and plug in the cable connector 86515 u Reconnect oil pipes Version with compressor wheel cooling system u Fit the O ring 42124 u Fit the air supply line See also chapter entitled Prelim...

Page 104: ...to crane using lifting device 90190 and shackle 90195 u Screw three press off nuts 61090 onto bearing casing studs equally distributed around circumference and screw up to end of thread by hand u Fit the compressor casing external part 74000 and secure with nuts 61037 u Secure three press off nuts 61090 against compressor casing 74000 by tightening them to specified torque see chapter Table of tig...

Page 105: ... lifting gear and swivel lifting eyes 90230 u Align wall insert 77000 with threaded holes in compressor casing in ternal part 76000 using spigots on swivel lifting eyes and lower it u Loop the lifting gear around the diffuser 79000 align it with the holes and lower it into position u Screw in the screw 76002 as far as it will go and then unscrew it by turn The screw must be loose and the diffuser ...

Page 106: ...ights reserved HZTL2481_EN Revision C May 2018 u Secure the lifting device 90190 and the shackle 90195 to the rear of the flange F u Carefully turn compressor casing internal part complete with wall in sert and diffuser about support angle 90025 into vertical position and set down on underlay and support angle Page 104 136 ...

Page 107: ...tightened u Fasten lifting device 90190 complete with shackle 90195 to front side of flange F u Fit O ring 76040 u Remove support angle 90025 u Fit four guide studs 90320 u Carefully put compressor casing internal part complete with wall in sert and diffuser over guide studs u Remove the guide studs 90320 and fit the studs 74026 74029 If provided u Use studs 10x 74029 and 2x 74026 each screwed in ...

Page 108: ...mpressor casing internal part 76000 The compressor casing internal part 76000 is now secure relative to the compressor casing external part 74000 NOTICE Note control dimension s The safety segments 76080 are again in the operating state Control dimension s mm Dimension mm TPL69 A TPL73 A TPL77 A s 11 3 12 1 12 9 u Put the nuts 90458 back in the toolbox u Measure and note axial clearance see sectio...

Page 109: ...ket 61050 may only be used once u Provide a new spiral wound gasket 61050 Disassembly u Remove the insulation from the gas inlet casing 51001 and discon nect the cleaning pipe if provided u Secure the gas inlet casing using a lifting gear CAUTION When looping the rope around the casing make sure that no cleaning pipes are crushed or damaged Do not under any circumstances fasten the lifting gear to...

Page 110: ...PL69 u Pull gas inlet casing 51001 together with nozzle ring 56001 away from gas outlet casing 61001 until the nozzle ring can be lifted out TPL73 TPL77 u Pull the gas inlet casing together with nozzle ring away from the gas outlet casing until holder 90175 can be fitted from the outside using screws 61044 and Verbus Ripp washers 61043 u Loosen the hexagon nuts 90178 on the studs u Fully withdraw ...

Page 111: ...tion disassembly Fig 1 u Remove screws 61044 and segments 51012 u Fit two studs 90177 in the bottom section u Pull gas inlet casing 51001 together with nozzle ring 56001 away from gas outlet casing 61001 until the nozzle ring can be lifted out u Fully withdraw the gas inlet casing and remove it CAUTION When setting down gas inlet casing use suitable underlays 1 If provided u Remove gasket 61050 Pa...

Page 112: ...ng and place holder 90175 over the nozzle ring Then tighten holder 90175 using screw 61044 and Verbus Ripp washer 61043 u Align gas inlet casing and secure using hexagon nuts 90178 on studs 90177 TPL69 u Insert and position nozzle ring TPL73 TPL77 u Remove holder 90175 and screw 61044 together with Verbus Ripp washers 61043 u Coat thread of screws 61044 with high temperature grease u Fit gas inlet...

Page 113: ...nd cams on the casing u Coat the screw threads with high temperature grease 1 If present u Fix a new spiral wound gasket 61050 in the slot using a little super glue for example Loctite 454 gel applied at three evenly distrib uted points u Position gas inlet casing complete with nozzle ring on gas outlet cas ing 61001 u Remove the two studs 90177 in the lower area u Fit the segment 51012 with the r...

Page 114: ... A30 TPL77 A10 A30 8 Disassembly and assembly 8 8 Dismantling and fitting nozzle ring at turbine end Copyright 2018 All rights reserved HZTL2481_EN Revision C May 2018 u Collars C of segments 51012 must be in slot S Page 112 136 ...

Page 115: ...component This enables simple and efficient tightening Tightening torques for screws 61044 Nm with spiral wound gasket Tightening TPL69 A TPL73 A TPL77 A Step 1 Screw in all screws hand tight Step 2 130 190 240 Step 3 260 370 480 Tightening torques for screws 61044 Nm without spiral wound gasket Tightening TPL69 A TPL73 A TPL77 A Step 1 Screw in all screws hand tight Step 3 260 370 480 Checking th...

Page 116: ...on Manual TPL69 A10 A30 TPL77 A10 A30 8 Disassembly and assembly 8 9 Table of tightening torques Copyright 2018 All rights reserved HZTL2481_EN Revision C May 2018 8 9 Table of tightening torques Page 114 136 ...

Page 117: ... M14 M16 04 74027 With washer M16 125 M18 170 M20 220 05 61036 74026 74029 M16 30 M18 80 M20 80 06 61044 61056 61059 M16 260 M18 370 M20 480 06b 61077 If provided M16 20 07 42059 42064 M16 105 M16 105 M20 240 10 61037 M16 105 M18 160 M20 210 11 61090 M16 10 M18 15 M20 20 14 86505 M18x1 5 150 M18x1 5 150 M18x1 5 150 21 90458 M8 20 M10 30 M10 30 1 Tighten the screw 76002 as far as it will go and the...

Page 118: ...ing on the situation stop the engine u Seal the oil leak u Soak up oil and dispose of in an environmentally compatible manner Wear safety gloves to protect against thermal hazards CAUTION Directives for taking out of operation Serious damage to engine or property can be caused by non compli ance with the directives for locking blanking off the turbocharger on the engine u Follow the directives of ...

Page 119: ...arious intermediate rings are provided with the locking device for dif ferent compressor wheels Attention must be paid to the compressor wheel type CV for the balancing screw holes The distance between the locking flange 94003 and the assembly disassembly device 90020 must be compensated using the intermediate rings 94001 and or 94002 depending on the compressor wheel version CAUTION During operat...

Page 120: ...6 105 M18 135 M20 175 94006 M8 25 M8 25 M8 25 94007 M8 15 M8 15 M8 15 NOTICE Carried out work as described in the chapter Disassembly and as sembly u Remove silencer or air suction branch and compressor casing internal part complete with wall insert and diffuser u Fit partition wall clamp 94005 using screws 90442 u Fit locking flange 94003 using nuts 74027 and then screws 94007 94006 and tighten a...

Page 121: ...eserved HZTL2481_EN Revision C May 2018 ð In the case of engines with three or four turbochargers the balancing screws should be removed from the compressor wheel concerned ð In the case of engines with one or two turbochargers eight screws are enough to securely fasten the locking flange Locking rotor Compressor type CV10 Page 119 136 ...

Page 122: ... or 94002 and assembly disas sembly device 90020 onto locking flange 94003 in correct order u Now push on remaining intermediate rings 94001 and or 94002 u Tighten intermediate rings assembly disassembly device 90020 and locking flange 94003 using screws 94006 according to values shown in preceding Table of tightening torques u Now tighten assembly disassembly device to compressor casing us ing nu...

Page 123: ...aged turbocharger must 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...

Page 124: ...l structural steel in accordance with DIN EN 10025 2 must be manufactured in house according to the drawing Cover plate dimensions mm Product B1 B2 B3 B4 B5 B6 B7 B8 TPL69 A 13 385 30 30 8 10 6 84 TPL73 A 450 50 50 9 12 8 94 TPL77 A 535 9 12 107 Product Ø 1 Ø 2 Ø 3 Ø 4 Ø 5 Ø 6 TPL69 A 726 818 779 18 25 15 TPL73 A 844 948 905 20 28 20 TPL77 A 1003 1124 1075 22 30 Product α 1 α 2 α 3 TPL69 A TPL77 A...

Page 125: ...30 9 Taking out of operation at short notice 9 3 Fit cover plate Copyright 2018 All rights reserved HZTL2481_EN Revision C May 2018 NOTICE Carry out the work as described in the chapter Removal and fitting u Remove cartridge group Page 123 136 ...

Page 126: ...ce 9 3 Fit cover plate Copyright 2018 All rights reserved HZTL2481_EN Revision C May 2018 u Close off opening in gas outlet casing using cover plate u Fasten cover plate using spacer sleeves and nuts 61037 CAUTION Shut off the supply of lubricating oil to the turbocharger Page 124 136 ...

Page 127: ... s instructions 4 stroke engine with several turbochargers Separate receivers 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 Common receiver The air line must be closed off at the engine end because the undam aged turbochargers build up a receiver pre...

Page 128: ...ger u 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 9 5 Bypass the turbocharger CAUTION Shut off the lubricating oil supply to the turbocharger w This applies to engines with one turbocharger only w The connections are ready and pipes for the bypass are available u Fit bypass around turbocha...

Page 129: ...ration and this is circulated by the pre lubrica tion pump no measures have to be taken Any remaining old engine oil will therefore be flushed away and the bearing sections largely protected against corrosion 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 u Do no...

Page 130: ...after taking an engine out of opera tion u Dismantle the turbocharger u The rotor and the bearing parts must be removed by an official ABB Turbocharging service station and refitted afterwards u Clean all parts u Machined bright surfaces of steel and cast parts must be oiled with anticorrosive oil u Reassemble complete turbocharger Rotor turning in stack draught If the rotor turns as a result of t...

Page 131: ...n indi vidual parts See the section Taking out of operation for up to 12 months under Mothballing measures for the measures always necessary when moth balling turbocharger parts If the turbocharger remains mounted on the engine refer to the section Taking out of operation for up to 12 months under Rotor turning in stack draught If the entire turbocharger is removed or if the turbocharger is re as ...

Page 132: ... 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 metallic materials filter components of fe...

Page 133: ...nto 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 u Parts showing signs of rust should be carefully cleaned and greased u Dispose of replaced and unusable parts in a professional and environ mentally compatible way Required customer spare part se...

Page 134: ...040 2 O ring 77005 77006 1 O ring 86506 TPL77 A Quantity Description Part number 15 Hexagon head screw 42059 42064 61044 61056 61059 15 Verbus Ripp washer 42058 42063 61043 61057 61058 3 Hexagon nut 61037 1 Gasket 42041 2 Gasket 42045 2 O ring 42012 76040 2 O ring 77005 77006 1 O ring 86506 TPL77 A Version with compressor wheel cooling Quantity Description Part number 15 Hexagon head screw 42059 4...

Page 135: ...stem if provided CAUTION Leaks Improper assembly of the cleaning pipe and the nozzles can lead to leaks and failure of the turbine cleaning system u 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 52218 Page 133 136 ...

Page 136: ...ual TPL69 A10 A30 TPL77 A10 A30 12 Spare parts 12 2 View of turbocharger with part numbers Copyright 2018 All rights reserved HZTL2481_EN Revision C May 2018 12 2 View of turbocharger with part numbers Page 134 136 ...

Page 137: ...ustomer 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 61037 in customer spare part set Hexagon nut 61076 1 if present Centering bolt 61077 1 if present Hexagon nut 63000 Turbine diffuser 68000 Foot 74018 Washer 74026 74029 Stud 74027 Hexagon nut 74000 Comp...

Page 138: ...EN Revision C May 2018 12 3 View of turbine cleaning system with part numbers optional 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 Page 136 136 ...

Page 139: ...ABB Turbo Systems AG Bruggerstrasse 71a CH 5400 Baden Switzerland ABB ...

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