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ABB HT845994, Operation Manual

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Operation Manual / TPL65-A10 / -A30

7  Removal and installation / 7.1  Turbocharger weights

© Copyright 2020 . All rights reserved.

HZTL2482_EN

Rev.E

March 2020

7 Removal 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]

TPL65

1230

Page 

77

 / 

117

Summary of Contents for HT845994

Page 1: ... ABB Turbocharging Type TPL65 A30 HT845994 nMmax 484 t Mmax 680 nBmax 470 t Bmax 650 1 s C 01230 36 24 24 Year 2021 Application according to the Operation Manual kg HZTL2482 English TPL65 A30 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: ... Safety instructions 16 2 5 Warning plates on the turbocharger 17 2 6 Safe operation and maintenance 18 2 7 Hazards during operation and maintenance 21 2 8 Periodic checking of the pressure vessel 26 2 9 Lifting loads 26 3 Start up 28 3 1 Oil supply 28 3 2 Inspection work 31 3 3 Commissioning after taking out of operation 33 4 Operation 34 4 1 Noise emissions 34 4 2 Servicing work 36 4 3 Replaceme...

Page 4: ... 5 Removing cartridge group 88 8 6 Dismantling and installing the turbine diffuser and nozzle ring 92 8 7 Installing cartridge group 96 8 8 Dismantling and fitting nozzle ring at turbine end 98 8 9 Table of tightening torques 101 9 Taking out of operation at short notice 103 9 1 Possibilities for emergency repair 103 9 2 Fit cover plate 104 9 3 Blocking the inlets and outlets 108 9 4 Bypass the tu...

Page 5: ...w 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 engine and the...

Page 6: ...reserved HZTL2482_EN Rev E March 2020 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 4 117 ...

Page 7: ...ylinders The exhaust gases escape to free air through an exhaust gas pipe which is connected to the gas outlet casing 06 The air which is necessary for operation of the diesel engine and is com pressed in the turbocharger is drawn through the suction branch or the filter silencer 01 into the compressor wheel 12 This air then passes through the diffuser 11 and leaves the turbocharger through the co...

Page 8: ...her type of use If the equipment is used for any other purpose ABB Turbocharging 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 the user or...

Page 9: ...otection 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 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...

Page 10: ...d In this case the turbochar ger must be inspected by an ABB Turbocharging Service Station and repacked u Inspect the package for damage If the package is damaged the tur bocharger must be inspected by an ABB Turbocharging Service Sta tion and repacked After every 3 years the following work steps must be performed by an ABB Turbocharging Service Station Inspect the component Replace the desiccant ...

Page 11: ...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 If the turbocharger shows modifications affecting safety or any cor responding operating behaviour it must be shut down immediately by stopping the engine The malfunction must be report...

Page 12: ...arts Operation of the turbocharger with non original parts can impair the safety of the turbocharger and can cause serious damage to property and injury to personnel u Only use original parts from ABB ABB accepts no liability for any damage resulting from the use of non original parts and corresponding accessories Competence of personnel The turbocharger must only be operated and serviced by train...

Page 13: ...t for a specific turbocharger variant ABB Turbocharging Service Stations will be happy to provide information on questions regarding a design variant see Contact information at www abb com turbocharging Accuracy of illustrations The illustrations in this document are general in nature and intended for ease of understanding Differences in detail are therefore possible Registered trademarks Register...

Page 14: ...ilitate the 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 com plied with Definition of caution warning The caution and warning signs are described in the chapter Safety ABB Turbocharging ABB Switzerland Ltd Turbocharging is identified as ABB Turbocharging in this ...

Page 15: ...eed 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 in kg 0...

Page 16: ...mally apply only when running at overload 110 during trials on the engine test bed Operation above nMmax and tMmax is not permit ted Non observance of the recommended replacement intervals increases 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 left and one on the right On turbochargers with insulati...

Page 17: ...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 safe and ...

Page 18: ...rotection 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 Warning signs ...

Page 19: ...t must be observed are attached to the turbocharger The warning plates must always be present in the intended locations and must be legible Fig 1 Warning plate Part number Size mm Product 81080 105 x 74 TPL 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 17 11...

Page 20: ...he 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 oil bi...

Page 21: ... 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 solvents are us...

Page 22: ...e 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 when taki...

Page 23: ...arger 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 Mechanical hazard...

Page 24: ... 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 WARNING...

Page 25: ...er 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 easily i...

Page 26: ...ination 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 adequately v...

Page 27: ... 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 the work a...

Page 28: ...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 must not be...

Page 29: ...ading 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 removed...

Page 30: ...mportant 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 lubricating oil filter system with a filter mesh size o...

Page 31: ...arger 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 turbocharger...

Page 32: ...g 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 operation and ...

Page 33: ...nated 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 supply lin...

Page 34: ...rature 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 after commi...

Page 35: ...fore 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 tion wor...

Page 36: ...harger 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 ally by ...

Page 37: ...opyright 2020 All rights reserved HZTL2482_EN Rev E March 2020 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 35 117 ...

Page 38: ...ned 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 Turbochar ging NOTICE Service inspection after 5 years To prevent age and stoppage related machine damage an insp...

Page 39: ...rer 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 to the ...

Page 40: ... 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 wheels and ins...

Page 41: ...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 influence the rep...

Page 42: ...O 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 components See ra...

Page 43: ...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 only sl...

Page 44: ... 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 following...

Page 45: ...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 up to the limit block 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 sea...

Page 46: ...ghts reserved HZTL2482_EN Rev E March 2020 4 5 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 44 117 ...

Page 47: ...s 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 silencer Compre...

Page 48: ...d 81005 Screw plug 81271 Lock 81006 Gasket 81136 Absorption segment 81135 Filter silencer body 81137 Sheet metal covering A Ribs E Insert unit absorption segment sheet metal covering fitted Removing and cleaning the filter silencer If provided u Remove filter ring 81265 u Rinse the filter ring 81265 using water with detergent additive or if it is heavily contaminated soak it and carefully squeeze ...

Page 49: ...t the absorption segments 81136 are only cleaned lightly with compressed air a soft brush or with moist cleaning cloths Otherwise segments may be damaged or lose their shape NOTICE Replace absorption segments which are heavily contaminated and the filter ring with original parts from ABB Fitting the filter silencer u Assemble the insert units E by inserting the absorption seg ments 81136 into the ...

Page 50: ...ed HZTL2482_EN Rev E March 2020 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 Screw 81273 Lock nut E Insert unit absorption segment sheetmetal covering Page 48 117 ...

Page 51: ... 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 absorption segments 81136 When cleaning...

Page 52: ...etal coverings 81137 back to original shape u Insert the insert units E into slot guides in filter silencer unit 81135 u Install cover grids 81266 uniformly and in the correct position u Push connecting rods 81269 through 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 T...

Page 53: ...tening 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 u Screw lock nuts 81273 onto screw 81272 and tighten to following torque Lock nut Tightening torque Nm 81273 40 If provided u Fit filter strip 81265 Page 51 11...

Page 54: ...nnels 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 the turboc...

Page 55: ...n 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 and cooling wa...

Page 56: ...en tested and is recommended by ABB Turbocharging the following pre requisites must be fulfilled u 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 fulfilled...

Page 57: ...g wait at 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 t...

Page 58: ... 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 essen...

Page 59: ...en 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 inlet tempe...

Page 60: ...erating state and prerequisites have been tested and approved by ABB Turbocharging 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 down u Star...

Page 61: ...ater 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 for at lea...

Page 62: ...dual 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 regard to draining the gas outlet casing The exhaust gas temperature behind the turbocharger drops signi ficantly when cleaning typi...

Page 63: ...itive 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 until a s...

Page 64: ...ta sheet u Comply with local legislation Wear safety goggles Wear safety gloves to protect against chemical hazards Wear a respiratory mask to protect against gases CAUTION Damage to coated nozzle rings The coating of coated nozzle rings can be damaged if cleaned improp erly u Only insert the nozzle ring in water u Only clean the nozzle ring with soft brushes u Do not sandblast the nozzle ring Bak...

Page 65: ...r Removal and in stallation u Remove cartridge group see chapter Disassembly and assembly First clean the compressor end and then the turbine end in accordance with the following description 5 5 4 Cleaning the cartridge group on the compressor end CAUTION Selection of the cleaning agent Cleaning agents that contain chlorine corrode metals u Only use pH neutral cleaning agents that do not corrode m...

Page 66: ... 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 soak the layers of contamination on the turbine the cartridge group can be immersed vertically in a container with fluid The cartridge group must be rotated to do this u Two cranes or chain blocks must be u...

Page 67: ...ing 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 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...

Page 68: ... 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 outlet f...

Page 69: ...til entire cartridge group is suspended from first crane 6 Remove loop from second crane CAUTION Selection of the cleaning agent Cleaning agents that contain chlorine corrode metals u Only use pH neutral cleaning agents that do not corrode metals u Observe the material safety data sheet u Observe country specific regulations regarding banned and restric ted substances u Fill the tank with soaking ...

Page 70: ... If water or contamination gets into the cartridge group the turbochar 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 respi...

Page 71: ...nation deposits lead to 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 be...

Page 72: ...or 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 tolerances must ...

Page 73: ...ging 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 condi ti...

Page 74: ... 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 gas pipe...

Page 75: ...on 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 volume too ...

Page 76: ...ometer 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 intake cond...

Page 77: ...ossible 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 Page 75 117...

Page 78: ...s 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 faulty trigger...

Page 79: ... Removal 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 TPL65 1230 Page 77 117 ...

Page 80: ...ch of the two oil supply pipes of the bearing casing When the cartridge group the bear ing casing or the turbocharger is being fitted to the engine it must be ensured that the orifices specified for the turbocharger are installed in both oil supply pipes u Check that the oil orifices have been correctly installed u Unplug the cable connector on the speed sensor u Remove the insulation at the suspe...

Page 81: ...g casing u Loosen the fixing screws at the foot u 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 turbocharger could tip over during installation or removal and cause a serious or even fatal injury u Wear personal protective equipment PPE u Support the turbocharger at a suitable point u ...

Page 82: ...ach of the two oil supply pipes of the bearing casing When the cartridge group the bear ing casing or the turbocharger is being fitted to the engine it must be ensured that the orifices specified for the turbocharger are installed in both oil supply pipes u Check that the oil orifices have been correctly installed u Adapt turbocharger to suit engine u Tighten fixing screws in foot in accordance wi...

Page 83: ...k on the cartridge group can lead to total system failure and void the warranty 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 Check visual...

Page 84: ...emblies or individual components only to lifting gear which is in technically perfect condition and has a suffi cient load limit 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 a component o...

Page 85: ... weights of individual parts or assemblies are guides roun ded off to the next highest value Assemblies Weights kg Description TPL65 01 Radial air suction branch 35 02 Axial air suction branch 25 03 Silencer 85 04 Compressor casing 150 05 Wall insert 50 06 Diffuser 22 07 Cartridge group 220 08 Turbine diffuser 30 09 Nozzle ring 10 10 Gas inlet casing radial 50 Page 83 117 ...

Page 86: ...ghts Copyright 2020 All rights reserved HZTL2482_EN Rev E March 2020 Complete compressor casing Weights kg TPL65 230 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 Page 84 117 ...

Page 87: ...ll air lines in accordance with the engine builder s instruc tions u Dismantle the insulation where necessary u 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 u Unscrew the nuts 72027 and remove them together with the wash ers 72018 u Remove the air suction branch and set it down to one ...

Page 88: ...lter 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 72027 and remove them together with washers 72018 u Remove filter silencer and set down to one side Installing the filter silen cer u Install filter silencer in reverse order Page 86 117 ...

Page 89: ...loves Wear safety gloves to protect against mechanical hazards The axial clearance A must be measured before removing and after fit ting the cartridge group u Measure and note the axial clearance A Axial clearance TPL65 Clearance A mm 0 39 0 56 CAUTION Clearances out of tolerance Clearances out of tolerance and excessively worn components can be the cause of serious damage to machinery and propert...

Page 90: ...asing When the cartridge group the bear ing casing or the turbocharger is being fitted to the engine it must be ensured that the orifices specified for the turbocharger are installed in both oil supply pipes u Check that the oil orifices have been correctly installed u Remove three studs 72029 at top u Attach lifting device 90190 to compressor casing 72000 then fasten and secure it to crane using ...

Page 91: ... down with surface F on underlay WARNING Tipping the compressor casing Make sure that the underlay does not slip u Allow compressor casing to rest only on surface F u Check the underlay and adjust it if necessary u Remove the screw 72002 u Remove the diffuser 79000 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...

Page 92: ...Remove the three screws 61059 together with their Verbus Ripp washers 61058 u Attach one lifting gear each to the two fins of the bearing casing provided for this purpose u Evenly press off cartridge group by screwing press off screws 90900 into the designated holes CAUTION If the rotor blades have insufficient or no clearance the blades and cas ing could be damaged u Check that the blades do not ...

Page 93: ...artridge group Copyright 2020 All rights reserved HZTL2482_EN Rev E March 2020 u Withdraw cartridge group and fit supports 90450 u Remove screws 42054 together with flange 42044 and also remove possible contamination behind the flange u Cover the oil connections Page 91 117 ...

Page 94: ...020 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 92 117 ...

Page 95: ... 2020 All rights reserved HZTL2482_EN Rev E March 2020 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 clamp hole and only loosen screws 61056 one after other u Do not yet remove the screws 61056 and Verbus Ripp washers 61057 Page 93 117 ...

Page 96: ...0 and the 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 crane u Remove...

Page 97: ... ring Copyright 2020 All rights reserved HZTL2482_EN Rev E March 2020 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 95 117 ...

Page 98: ...the turbocharger is being fitted to the engine it must be ensured that the orifices specified for the turbocharger are installed in both oil supply pipes u Check that the oil orifices have been correctly installed u Remove the cover from the oil connection u Fit flange 42044 with screws 42054 and new gasket 42045 u Attach one lifting gear each to the two fins of the bearing casing provided for thi...

Page 99: ...user 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 Fit O rings 77005 77006 u Fit lifting gear swivel lifting eye 90230 and plug bolt 90865 u Align the wall insert 77000 to the threaded holes in the compressor casing 72000 using the lugs on the swivel lifting eyes then lower...

Page 100: ...t compressor casing 72000 by tightening to specified torque See chapter Table of tight ening torques u Remove lifting device 90190 u 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 u Have components assessed and if ne...

Page 101: ...o not fasten the lifting gear to cleaning pipes under any circumstances u Remove two hexagon head screws 61044 together with Verbus Ripp washers 61043 from the bottom section and replace them with two studs 90177 u To secure screw hexagon nuts 90178 onto studs 90177 u Loosen and remove the remaining screws 61044 and Verbus Ripp washers 61043 from the gas inlet casing flange 61001 u Pull gas inlet ...

Page 102: ...sket 61050 into slot in gas inlet casing 61001 u Align gas inlet casing and secure using hexagon nuts 90178 on studs 90177 u Insert nozzle ring 56001 and position it u Brush screw threads 61044 with high temperature grease u Fit the gas inlet casing flange to the gas outlet casing using screws 61044 and Verbus Ripp washers 61043 then tighten it u Remove the hexagon nuts 90178 from the studs 90177 ...

Page 103: ...Operation Manual TPL65 A10 A30 8 Disassembly and assembly 8 9 Table of tightening torques Copyright 2020 All rights reserved HZTL2482_EN Rev E March 2020 8 9 Table of tightening torques Page 101 117 ...

Page 104: ...rt number TPL65 01 82005 M16x1 5 45 03 1 72002 M10 04 72027 With washer M14 95 05 61036 72029 M14 30 06 61044 61059 M14 160 61056 M14 150 06b 61077 If provided M14 20 07 42059 42064 M12 45 10 61037 M14 75 11 61090 M14 10 14 86505 M18x1 5 150 1 Screw in the screw 72002 as far as it will go and then un screw it by turn The screw must be loose and the diffuser must be movable Page 102 117 ...

Page 105: ...Machine damage in emergency operation The assembly of the locking device on the turbocharger is only permiss ible in emergencies It is not permitted to lock the rotor for an engine test Serious damage to engine or property can be caused by non com pliance with the regulations in the event of an emergency u The permissible turbocharger speed for the unlocked turbocharger may not exceed 45 of nBmax ...

Page 106: ...t cover plate NOTICE The cover plate material General 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 TPL65 13 325 30 30 8 10 6 70 Product Ø 1 Ø 2 Ø 3 Ø 4 Ø 5 Ø 6 TPL65 616 694 660 16 22 15 Product α 1 α 2 α 3 TPL65 4 x 90 37 5 24 x 15 Page 104 117 ...

Page 107: ...Taking out of operation at short notice 9 2 Fit cover plate Copyright 2020 All rights reserved HZTL2482_EN Rev E March 2020 NOTICE Carry out the work as described in the chapter Removal and fitting u Remove cartridge group Page 105 117 ...

Page 108: ...2 Fit cover plate Copyright 2020 All rights reserved HZTL2482_EN Rev E March 2020 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 106 117 ...

Page 109: ...ctions 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 pressure CAU...

Page 110: ...t 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 4 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 turbocharger NOTI...

Page 111: ...d 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 not breathe...

Page 112: ...ing 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 the stack ...

Page 113: ...dual 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 sembled f...

Page 114: ...ask 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 felt and polyethyl...

Page 115: ...is 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 set 97070 Quantity Descri...

Page 116: ...f provided CAUTION Leaks Improper assembly of the cleaning pipe and the nozzles can lead to leaks and failure of the turbine cleaning system u Have work on the turbine cleaning system carried out by an ABB Tur bocharging 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 114 117 ...

Page 117: ...n Manual TPL65 A10 A30 12 Spare parts 12 2 View of the turbocharger with part numbers Copyright 2020 All rights reserved HZTL2482_EN Rev E March 2020 12 2 View of the turbocharger with part numbers Page 115 117 ...

Page 118: ... 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 if provided Centering bolt 61077 if provided Hexagon nut 63000 Turbine diffuser 68000 Foot 72000 Compressor casing 72018 Washer 72029 Stud 72027 Hexagon nut 77000 W...

Page 119: ... E March 2020 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 117 117 ...

Page 120: ...ABB Switzerland Ltd Turbocharging Bruggerstrasse 71a CH 5401 Baden Switzerland ...

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