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Operation Manual / TPL65VA10 / VA30

Preliminary remarks

1

Turbocharger rating plate

1.7

Page 15

© Copyright 2016 ABB. All rights reserved.

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ov

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2016

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L2487_

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Turbocharger rating plate

1.7

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

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

ginebuilder.

02 Turbocharger operating limits during operation

03    Replacement interval for plain bearings in 1000 h
04    Replacement interval for compressor in 1000 h
05    Replacement interval for turbine in 1000 h

06  Customer part number
07  Designation of the special design
08  Turbocharger weight in kg
09  Turbocharger type
10  Serial number
11  Year of construction of turbocharger
12  Manufactur

ing

plant

1.7

Operating limits

Recommended replace-

ment intervals for turbo-

charger components

Further information

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Summary of Contents for TPL65VA10

Page 1: ... Systems Ltd CH 5401 Baden Type TPL65VA10 HT844106 nMmax 503 t Mmax 650 nBmax 478 t Bmax 620 1 s C 01210 35 50 50 Year 2018 made in Switzerland Application according to the Operation Manual kg HZTL2487 English TPL65VA10 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: ... 8 Contact information 2 Safety 2 1 Introduction 2 2 CE conformity 2 3 Definition of mandatory signs 2 4 Definition of Safety instructions 2 5 Warning plates on the turbocharger 2 6 Safe operation and maintenance 2 7 Hazards during operation and maintenance 2 8 Periodic checking of the pressure vessel 2 9 Lifting loads 3 Start up 3 1 Oil supply 3 2 Inspection work 3 3 Commissioning after taking ou...

Page 4: ...ariable Turbine Geometry 7 Removal and installation 7 1 Turbocharger weights 7 2 Removing the turbocharger 7 3 Installing the turbocharger 8 Disassembly and assembly 8 1 Introduction 8 2 Module weights 8 3 Removing and fitting filter silencer or air suction branch 8 4 Axial clearance 8 5 Removing cartridge group 8 6 Removing and fitting turbine diffuser 8 7 Removing variable turbine geometry modul...

Page 5: ...016 HZTL2487_EN Revision C 10 Mothballing the turbocharger 10 1 Taking the engine out of operation for up to 12 months 10 2 Taking the engine out of operation for more than 12 months 11 Disposing of turbocharger components 12 Spare parts 12 1 Ordering spare parts 12 2 View of turbocharger with part numbers ...

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Page 7: ...B Turbo Systems and to use it as intended It provides important information in order that the turbocharger can be op erated safely correctly and efficiently This Operation Manual complements and expands existing national regu lations concerning work safety and accident prevention Target group This Operation Manual is intended for engineers and qualified mechanics who are responsible for operating ...

Page 8: ...eserved November 2016 HZTL2487_EN Revision C Layout and function 1 2 01 Filter silencer 08 Nozzle ring 02 Radial plain bearing 09 Turbine wheel 03 Thrust bearing 10 Bearing casing 04 Bearing bush 11 Diffuser 05 Radial plain bearing 12 Compressor wheel 06 Gas outlet casing 13 Air outlet casing 07 Gas inlet casing 1 2 ...

Page 9: ...ed air into the cylinders 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 fil ter silencer 01 into the compressor wheel 12 It then passes through the diffuser 11 and leaves the turbocharger th...

Page 10: ...ry remarks 1 Layout and function 1 2 Page 8 Copyright 2016 ABB All rights reserved November 2016 HZTL2487_EN Revision C Additional function TPL V These turbocharger types have adjustable guide vanes at the turbine end instead of a nozzle ring ...

Page 11: ...ufacturer accepts no liability for other applications If it is used otherwise ABB Turbo Sys tems reserves the right to reject all warranty claims This turbocharger was built according to state of the art technology and is operationally safe according to recognised safety regulations WARNING Improper operation and maintenance of the turbocharger can result in danger to life and limb of the user or ...

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

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

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

Page 15: ...corresponding accessories Competence of personnel The turbocharger must only be operated and serviced by trained and au thorised personnel Basic mechanical training is a prerequisite Design variants This document is valid for different design variants of turbochargers There may be sections and descriptions of components that are not rele vant for a specific turbocharger variant ABB Turbocharging S...

Page 16: ...he product Definition of mandatory signs Mandatory signs show the protective equipment to be worn for a task The mandatory signs are described in chapter Safety and must be complied with Definition of caution warning The caution and warning signs are described in the chapter Safety ABB Turbo Systems In this document ABB Turbo Systems Ltd is abbreviated to ABB Turbo Systems Official ABB Turbo Syste...

Page 17: ...ith the en ginebuilder 02 Turbocharger operating limits during operation 03 Replacement interval for plain bearings in 1000 h 04 Replacement interval for compressor in 1000 h 05 Replacement interval for turbine in 1000 h 06 Customer part number 07 Designation of the special design 08 Turbocharger weight in kg 09 Turbocharger type 10 Serial number 11 Year of construction of turbocharger 12 Manufact...

Page 18: ...that you contact the nearest official ABB Turbocharging service station nMmaxand tMmax normally apply only when running at overload 110 during tri als on the engine test bed These limits can also be permitted during operation for special applications Operation above nMmax and tMmax is not permitted Non observance of the recommended replacement intervals can increase the risk of unpredictable compo...

Page 19: ...eserved November 2016 HZTL2487_EN Revision C Contact information 1 8 Contact information Contact information for the official service stations of ABB Turbo Systems is available online Scan the QR code to access our website ABB Turbo Systems Ltd Bruggerstrasse 71a CH 5401 Baden Switzerland www abb com turbocharging 1 8 ...

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

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

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

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

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

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

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

Page 28: ...sure level is above 85 dB A always wear ear protection Wear ear protection Hazards due to hot surfaces and substances During operation turbocharger surfaces and attached parts as well as op erating materials lubricating oil become hot The surface temperature is dependent on the effectiveness of the insulation being used The tem perature can become high enough so that it falls into ranges where bur...

Page 29: ...hot turbocharger surfaces must be observed in every case Hazards due to operating and auxiliary materials Operating and auxiliary materials are substances used for operation or the execution of maintenance work Oils greases coolants cleaning agents and solvents acids etc can be regarded as hazardous materials Operat ing and auxiliary materials can be combustible and easily ignited WARNING Handling...

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

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

Page 32: ...erved November 2016 HZTL2487_EN Revision C Hazards due to electrical components WARNING Hazards due to electrical components Electrical components operate with voltages which can present hazards to humans All work on or with electrical components may only be performed by trained specialists Heed any country specific regulations ...

Page 33: ...e so called simple pressure vessels The local statutory regulations covering periodic checks of pressure vessels must be observed The operator is responsible for the safe operation of the pressure vessel WARNING Hazards from pressure vessels The operator must keep the pressure vessel in a proper condition and monitor it Necessary repair or maintenance work must be carried out without delay and the...

Page 34: ...e stand beneath a suspended load Wear safety gloves against mechanical risks Wear safety helmet In the case of two or more suspension points the slinging angle must not exceed 45 This avoids excessive loading due to inclined tensile loading Fasten turbocharger assemblies components as described in respec tive handling steps Before attaching slings allow turbocharger components to cool down maximum...

Page 35: ...tions is an important prerequisite for trouble free tur bocharger operation The turbocharger is normally lubricated with oil from the engine oil circuit NOTICE With regard to the oil supply please observe the engine builder s speci fications for lubricating oil selection oil change intervals oil filtration oil pressure and oil temperature Oil filtration A lubricating oil filter system with a filte...

Page 36: ... turbocharger are listed below Status for operation Oil pressure in front of the turbo charger poil in bar Permissible for normal operation 1 3 2 5 Permissible during engine warm up 1 3 5 0 Temporarily admissible 1 h alarm 1 1 1 3 Not permissible emergency stop 0 0 1 1 Permissible during pre and post lubrication engine stopped 0 2 2 5 NOTICE Oil orifice A metering orifice is installed in the oil i...

Page 37: ...il 30 Lubricating oil temperature at the outlet The oil temperature at the outlet is mainly dependant on Lubricating oil temperature and pressure at the oil inlet Engine load and turbocharger speed Exhaust gas temperature The maximum admissible oil temperature at the outlet is listed in the fol lowing table The specified oil outlet temperature is to be considered as alarm value for the turbocharge...

Page 38: ...oning Inspect for damage Check oil filter for cleanliness before commissioning CAUTION It is urgently recommended that the entire lubricating system be flushed thoroughly with warm oil using a bypass pipe before starting up the first time commissioning and after all service work on the lubricating sys tem It is urgently recommended that a running in filter is used when running in the engine and af...

Page 39: ...air temperature in front of and behind the compressor Check the functioning of the variable turbine geometry module The measured values must be compared with the values in the ac ceptance test report while taking different operating conditions into ac count NOTICE Lubricants and pastes used during assembly of the turbocharger liquefy or vaporise and might escape as an oily liquid in the first few ...

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

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

Page 42: ... 40 Copyright 2016 ABB All rights reserved November 2016 HZTL2487_EN Revision C Suggestion for noise insulation of the bellows 01 Compressor casing 04 Insulation pads 02 Bellows 05 Insulation mat at least 15 mm 03 Charge air duct scavenging air line 06 Sheet metal cover ...

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

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

Page 45: ...orrosion Clean bearing casing and blow air through oil ports Inspect and assess sealing air lines Inspect and assess rotor and bearing parts Have the variable turbine geometry module overhauled by ABB Turbo Systems ABB Turbocharging Service Stations have variable turbine geometry modules replaced with overhauled ones as part of the CPEX Customer Part Exchange programme Service work every 30000 hou...

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

Page 47: ...ing 50000 100000 Variable turbine geometry module The variable turbine geometry module can be replaced with a CPEX variable turbine geometry module by an ABB Turbocharging service station 15000 Turbine diffuser cover ring 35000 50000 Other casings 100000 Axial bearing components 24000 36000 Radial bearing components 24000 36000 Turbine blades due to wear Rotor components See the data on the rating...

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

Page 49: ...ded the following steps must be carried out Reduce engine performance immediately until the highest turbo charger speed no longer exceeds 70 of nBmax If the engine cannot be stopped continue to run at this reduced engine performance or turbocharger speed If the turbocharger surges continuously engine performance must be reduced further Measure the temperatures in the air and gas lines to and from ...

Page 50: ...adopted to fit it Engine and turbocharger are not running The turbocharger lubricating system is switched off Remove screw plug 42047 from bearing casing NOTICE Part position The position of the screw plug for measuring the speed is marked n on the bearing casing Screw in speed sensor 86505 as far as it will go and tighten to torque specified in table See chapter Table of tightening torques Connec...

Page 51: ...stop the engine Switch off the lubricating oil supply to the turbocharger Disconnect the cable connector from the speed sensor Screw out defective speed sensor Screw in a new speed sensor up to the limit block Observe the tightening torque see the table of tightening torques in the chapter entitled Disassembly and assembly NOTICE Sealing of the speed sensor The speed sensor is designed with a seal...

Page 52: ...mergency operation TPL VA 4 5 In the event of failure of the control system or the drive the variable tur bine geometry module can be fixed by clamping the ring lever B using at least 3 washers C spaced around the circumference When fixing the position of the variable turbine geometry module and or the blades must be specified by the enginebuilder 4 5 Detail A ...

Page 53: ...B All rights reserved November 2016 HZTL2487_EN Revision C Stopping the engine 4 6 CAUTION Stopping the engine Heat in the turbocharger must be dissipated by the further circulating lubricating oil Allow the engine to continue running at idling speed for a further 10 minutes before stopping 4 6 ...

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Page 55: ... visual checks and clean ing to ensure that the turbocharger and its attached units function trouble free The external condition and how dirty the cleaning points specified in this chapter are must be established by visual checks at the specified intervals The safety precautions must be observed during all maintenance and servicing work The cleaning points described in the following are Filter sil...

Page 56: ...Tension band 81005 Screw plug 38271 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 Remove filter ring 81265 Rinse the filter ring 81265 using water with detergent additive or if it is heavily contaminated soak it and carefully squeeze it ou...

Page 57: ...uring cleaning ensure that the absorption segments 81136 are only cleaned with a mild jet of compressed air soft brush or a damp cloth 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 Turbo Systems Fitting the filter silencer Assemble the insert units E by inserting the absorptio...

Page 58: ...Filter silencer body 81272 Screwdriver 81273 Lock nut E Insert unit absorption segment sheet metal covering Removing and cleaning filter silencer Remove filter strip 81265 Rinse filter strip 81265 using water with detergent additive or if very dirty soak it and squeeze out carefully Rinse it in cold water Avoid rough treatment not a jet of water NOTICE How dirty the filter strip 81265 is depends o...

Page 59: ...ing rods 81269 Carefully remove cover grids 81266 Pull out insert units E bend open sheet metal coverings 81137 and then remove absorption segments 81136 Clean the absorption segments 81136 During cleaning 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 ...

Page 60: ...81137 Bend sheet metal coverings 81137 back to original shape Insert the insert units E into slot guides in filter silencer unit 81135 Uniformly place cover grids 81266 in correct position Push connecting rods 81269 through lugs of cover grids 81266 CAUTION If the connecting rods 81269 are not correctly positioned in their re cesses on the filter silencer unit 81135 the cover grid 81266 can twist ...

Page 61: ...s 81272 When tightening the screws 81272 ensure that connecting rods 81269 are located correctly in recesses in filter silencer body 81135 Now tighten screws 81272 alternately until the following maximum torque is reached Screw Tightening torque Nm 81272 20 Screw lock nuts 81273 onto screw 81272 and tighten to following torque Lock nut Tightening torque Nm 81273 40 Fit filter strip 81265 If provid...

Page 62: ...t or dust are in the intake air Consequences of contamination Impaired compressor efficiency Higher exhaust gas temperatures Increased fuel consumption Increased rotor unbalance Periodic cleaning of the compressor during operation prevents or delays a severe increase of the contamination It does not however replace the regular service work during which the turbocharger is completely disman tled an...

Page 63: ... injection pipe fitted in the filter silenc er or the suction branch The water does not act as a solvent but the dirt deposit is removed by the mechanical impact of the droplets This is a very suitable process provid ed that the degree of contamination is not too high CAUTION Corrosion and deposits when cleaning Damage and impairment of turbocharger parts due to salt water and cooling water additi...

Page 64: ...ocess which has been tested and is recommended by ABB Turbo Systems the following pre requisites must be fulfilled Engine load 50 85 Start of cleaning cycle in accordance with following description for wet cleaning operation with XC3 Compressor wet cleaning procedure with XC3 It is mandatory to fulfil the operating condition prerequisites before cleaning compressors with XC3 Remove the sealing plu...

Page 65: ...been injected After cleaning wait at least 5 minutes to allow the turbocharger to dry NOTICE If the cleaning operation is not satisfactory it may be repeated up to two times If the cleaning results are still not satisfactory after three attempts and the engine values are also unsatisfactory we recommend that you have the turbocharger inspected and cleaned by an official ABB Turbocharg ing Service ...

Page 66: ...ight 2016 ABB All rights reserved November 2016 HZTL2487_EN Revision C Cleaning turbines and guide vanes during operation 5 4 NOTICE HFO applications The TPL65VA has not been released for HFO applications Wet clean ing of the turbine blades and guide vanes during operation is thus nei ther required nor planned 5 4 ...

Page 67: ... to mechanical damage The use of needle guns or other impact tools for example damages the components Depending on the specification nozzle rings have protec tive coatings which can also be damaged Only use soft tools such as scouring cloths brushes or wire brushes In the event of heavy contamination the cleaning methods described in this chapter such as soaking can be repeated until a satisfactor...

Page 68: ...inst mechanical risks Wear a respiratory mask to protect against gases Baked on layers of contamination for example from heavy fuel oil or coked oil occur at the turbine end The following performance relevant parts can be cleaned according to the following description 56001 Nozzle ring 63000 Turbine diffuser Place contaminated parts in hot water or in a liquid such as carbon remover so that the co...

Page 69: ... agent Cleaning agents which contain chlorine attack metals Use only pH neutral cleaning agents which do not attack metals Observe safety data sheet CAUTION Water and contamination in the cartridge group If water or contamination penetrates the cartridge group this can impair the function of the turbocharger and damage parts inside the cartridge group Make sure that no water or contamination can e...

Page 70: ...be submerged vertically in a tank with liquid The cartridge group must be rotated to do this Two cranes or chain blocks must be used for the rotating operation Suspending the chain block directly from the crane and rotating the cartridge group is not permitted because of the risk of damage to the compressor wheel Cartridge group with a central suspension point CAUTION Damage to compressor wheel Th...

Page 71: ...reserved November 2016 HZTL2487_EN Revision C 4 When the cartridge group is horizontal secure one chain block from one of the upper push off threads using a swivel lifting eye and sus pend from the second crane 5 Tighten chain block until entire cartridge group is suspended from second crane 6 Remove loop from first crane ...

Page 72: ...l The lifting gear must not touch the compressor wheel at any time during rotation Choose appropriate lifting gear length 1 Suspend cartridge group from the two side suspension points on the crane using two lifting loops or Attach two swivel lifting eyes to the side and suspend the cartridge group from the crane using two lifting loops 2 Attach third lifting loop with swivel lifting eye to thread ...

Page 73: ...l lifting eye and attach to the first crane 5 Tighten chain block until entire cartridge group is suspended from first crane 6 Remove loop from second crane CAUTION Selection of the cleaning agent Cleaning agents which contain chlorine attack metals Use only pH neutral cleaning agents which do not attack metals Observe safety data sheet Fill the tank with soaking liquid Only immerse the cartridge ...

Page 74: ...tion in the cartridge group If water or contamination gets into the cartridge group the turbocharger function may be impaired and parts in the cartridge group may be dam aged Place cartridge group on suitable wooden or metal supports Allow the layers of contamination on the turbine to soak for at least four hours Removing contamination WARNING Health hazard due to soot particles If soot particles ...

Page 75: ...ibuted residual contamination deposits lead to rotor unbalance This can result in bearing or turbocharger damage Remove all traces of contamination from the turbine After brushing off the contamination fill the tank with clean water not salt water Submerge the turbine of the cartridge group in clean water so that loose particles of contamination detach completely Lift the cartridge group Dry turbi...

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Page 77: ...o charger Rotor unbalance Contact an ABB Turbocharging Service Station Damaged turbine or compressor Damaged bearing Rubbing of rotating parts Normal behaviour no malfunction Turbo charger Minor uniform wear around the periphery of rotor components caused by slight local rubbing of adjacent components is permis sible The compressor blades and turbine blades are then short ened somewhat Certain tol...

Page 78: ...ed or periodic surging Possible damage to components such as the compressor wheel tur bine blades bearings and filter silencer Have the cause clarified immediately by an ABB Turbocharging ser vice station and rectified Have components inspected for damage and if necessary replaced by an ABB Turbocharging service station Sporadic surge blows Surging of the turbocharger can occur during certain oper...

Page 79: ... Turbo charger Rotor axial clearance too large Contact an ABB Turbocharging Service Station Reduction in speed Possible causes Elimination Engine Defects of connected cylinders when pulse charging Contact the enginebuilder Turbo charger Heavy contamination of the tur bine Clean it Damaged rotor components or bearing Contact an ABB Turbocharging Service Station Pipes Defects such as leaks in the ex...

Page 80: ...ir it or contact the manufac turer Turbocharger Air starvation for example filter silencer clogged with dirt Clean it Compressor turbine contaminated Exhaust counterpressure too high Clean or repair the boiler or ex haust silencer Damaged or eroded turbine Contact an ABB Turbocharging Service Station Charge air cooler Cooler contaminated Clean it Cooling water volume too low Top up the water Entry...

Page 81: ...ng Replace the manometer Line to manometer leaking Repair the leak Contaminated filter silencer causing excessive loss of pres sure Clean it Compressor turbine contaminated Damaged compressor turbine Contact an ABB Turbocharging Service Station Exhaust counterpressure too high Clean or repair the boiler or ex haust silencer Charge air pressure too high Engine performance and engine speed unchanged...

Page 82: ...ring run down Possible causes Elimination Turbo charger Turbocharger contaminated Clean it Damaged bearing Contact an ABB Turbocharging Service Station Rubbing rotor Foreign object in turbocharger Run down time too short Possible causes Elimination Turbo charger Turbocharger contaminated Clean it Damaged bearing Contact an ABB Turbocharging Service Station Rubbing rotor Foreign object in turbochar...

Page 83: ... cause problems for the evaluation electronics This problem is eliminated by removing the gasket Defective sensor Contact ABB Turbocharging service station Measured speeds too high Dirty sensor tip The sensor tip is magnetic and can thus at tract metal particles As a result the dis tance to the auxiliary bearing decreases which can lead to amplification of the noise component and consequently to f...

Page 84: ...r 2016 HZTL2487_EN Revision C Variable Turbine Geometry 6 6 Variable Turbine Geometry VTG not adjustable Possible causes Elimination Turbocharger Heavy turbine contamination Contact an ABB Turbocharging Service Station VTG bearing damaged Drive unit electrical components No drive energy Contact an ABB Turbocharging Service Station 6 6 ...

Page 85: ...evision C Removal and installation Turbocharger weights 7 1 Lifting gear with a sufficient load limit must be used for removing and in stalling the turbocharger The following weight specification is the heaviest variant possible This standard value may deviate from the data on the rating plate depending on the specification TPL65VA10 30 1210 7 7 1 Weight kg ...

Page 86: ...re is fitted in each of the two oil inlet channels in the bearing casing When the cartridge group the bearing casing or the turbocharger is fitted to the engine it must be en sured that the orifice plates that are specified for the turbocharger have been installed in the two oil inlet channels Check correct installation of oil orifice plates Unplug the cable connector on the speed sensor Remove th...

Page 87: ...lace a sling around the bearing casing Loosen the fixing screws at the foot Lift the turbocharger off the engine and set it down to one side WARNING Beware of tilting If support for the turbocharger is not provided or is inadequate the tur bocharger could tip over during installation or removal and cause a se rious or even fatal injury Support the turbocharger at a suitable point If possible secur...

Page 88: ...ure is fitted in each of the two oil inlet channels in the bearing casing When the cartridge group the bearing casing or the turbocharger is fitted to the engine it must be en sured that the orifice plates that are specified for the turbocharger have been installed in the two oil inlet channels Check correct installation of oil orifice plates Adapt turbocharger to suit engine Tighten fixing screws...

Page 89: ...sitions for assembly ABB Turbo Systems recommends that the casing positions are marked before disassembling the turbocharger Identifying assembly devices Not all assembly devices are marked with a part number They can be identified using the tool list This list is enclosed in the toolbox WARNING Maintaining assembly devices Assembly devices must be checked for damage before and after use Visually ...

Page 90: ...ttach turbochargers assemblies or individual components only to lifting gear which is in technically perfect condition and has sufficient load capacity Make sure the load is suspended properly on the crane hook Do not let anyone stand beneath a suspended load Wear safety gloves against mechanical risks Wear safety helmet Definition of terms Suspension point Defined load carrying point on a compone...

Page 91: ... specified weights of individual parts or assemblies are guides round ed off to the next highest value Assemblies Item Description TPL65VA10 30 01 Radial air suction branch 35 02 Axial air suction branch 25 03 Filter silencer 85 04 Compressor casing 150 05 Wall insert 50 06 Diffuser 22 07 Cartridge group 220 08 Turbine diffuser 30 09 Variable turbine geometry module 55 8 2 Weights kg ...

Page 92: ...ge 90 Copyright 2016 ABB All rights reserved November 2016 HZTL2487_EN Revision C Complete compressor casing TPL65VA10 30 230 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 Weight kg ...

Page 93: ...g filter silencer or air suc tion branch 8 3 Remove insulation where necessary Fit swivel lifting eye 90231 to filter silencer Or Pass lifting gear through rib on filter silencer Pass lifting gear through lugs at back Unscrew nuts 72027 and remove them together with washers 72018 Remove filter silencer and set down to one side Install filter silencer in reverse order 8 3 Remove filter silencer Ins...

Page 94: ...builder s instruc tions Dismantle the insulation where necessary Pass a lifting gear around the air suction branch It is permissible to pass the lifting gear through holes possibly provided in the ribs to im prove stability Unscrew the nuts 72027 and remove them together with the washers 72018 Remove the air suction branch and set it down to one side Fit the air suction branch in reverse order Rem...

Page 95: ...n injury Wear safety gloves Wear safety gloves against mechanical risks The axial clearance A must be measured before removing and after fit ting the cartridge group 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 ...

Page 96: ...up the bearing casing or the turbocharger is fitted to the engine it must be en sured that the orifice plates that are specified for the turbocharger have been installed in the two oil inlet channels Check correct installation of oil orifice plates Loosen and remove sealing air line 56501 between compressor cas ing 72000 and variable turbine geometry module 56100 Remove three studs 72029 at top At...

Page 97: ...diffuser and set them down with surface F on underlay WARNING Tipping the compressor casing Make sure that the underlay does not slip Allow compressor casing to rest only on surface F Check the underlay and adjust it if necessary Remove the screw 72002 Remove the diffuser 79000 Carefully press off the wall insert 77000 using the press off screws 90900 and remove it using the swivel lifting eye 902...

Page 98: ...he O ring 42012 Remove the three screws 61059 together with their Verbus Ripp washers 61058 Attach one lifting gear each to the two fins of the bearing casing pro vided for this purpose 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 Check that the bla...

Page 99: ...8 Removing cartridge group 8 5 Page 97 Copyright 2016 ABB All rights reserved November 2016 HZTL2487_EN Revision C Withdraw cartridge group and fit supports 90450 Remove screws 42064 flange 42044 and gasket 42045 and clean oil space Cover the oil connections ...

Page 100: ...turbine diffuser 8 6 Replace two screws 61032 with two studs 90903 in upper section of turbine diffuser Screw out the remaining screws 61032 press off the turbine diffuser 63000 using the press off screws 90901 then withdraw and re move it Fitting the turbine diffuser Fit the turbine diffuser in reverse order of removal NOTICE Brush high temperature grease on all screws at and in the gas outlet ca...

Page 101: ...et casing 51001 together with variable turbine geom etry module 56100 CAUTION After removing screws 56122 and retaining clips 56121 gas inlet casing 51001 is no longer secured Loosen screws 56122 together with retaining clips 56121 and re move with clamping ring 56112 Remove clamping ring 56112 Carefully separate gas inlet casing 51001 from variable turbine ge ometry module 56100 and remove it CAU...

Page 102: ...TL2487_EN Revision C Fitting the variable turbine geometry module and the gas inlet casing 8 8 Push variable turbine geometry module 56100 over studs Push gas inlet casing 56001 over studs Slide clamping ring 56112 onto studs Tighten nuts 61042 to specified torque Fit retaining clips 56121 using screws 56122 Fit semi circular section of sealing air line A to variable turbine ge ometry module 8 8 ...

Page 103: ...mbly and assembly 8 Fitting the variable turbine geometry module and the gas inlet casing 8 8 Page 101 Copyright 2016 ABB All rights reserved November 2016 HZTL2487_EN Revision C Fit sealing air line 56501 to semi circular section of line A ...

Page 104: ...the cartridge group the bearing casing or the turbocharger is fitted to the engine it must be en sured that the orifice plates that are specified for the turbocharger have been installed in the two oil inlet channels Check correct installation of oil orifice plates Remove the cover from the oil connection Fasten separate lifting gear to each of the two ribs on the bearing cas ing provided for this...

Page 105: ...at the blades do not rub against the turbine diffuser Remove the lifting gear Fit the O ring 42012 Screw in the speed sensor 86505 along with the O ring 86506 and plug in the cable connector 86515 Fit the O rings 77005 77006 Fit the lifting gear and the swivel lifting eye 90230 Align the wall insert 77000 to the threaded holes in the compressor casing 72000 using the lugs on the swivel lifting eye...

Page 106: ...gainst compressor casing 72000 by tightening them to specified torque See chapter Table of tightening torques Remove lifting device 90190 Fit sealing air line 56501 between compressor casing 72000 and variable turbine geometry module 56100 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 c...

Page 107: ...Operation Manual TPL65VA10 VA30 Disassembly and assembly 8 Installing cartridge group 8 9 Page 105 Copyright 2016 ABB All rights reserved November 2016 HZTL2487_EN Revision C ...

Page 108: ...ion Manual TPL65VA10 VA30 Disassembly and assembly 8 Table of tightening torques 8 10 Page 106 Copyright 2016 ABB All rights reserved November 2016 HZTL2487_EN Revision C Table of tightening torques 8 10 8 10 ...

Page 109: ...sher M14 100 04 72002 M10 1 06 61037 M14 80 07 61090 M14 10 08 61036 61041 72029 M14 50 09 61059 M14 160 13 42059 42064 M12 50 17 61056 M14 150 18 51075 56110 56114 M8 25 19 61042 M14 130 24 56122 M10 50 30 86505 M18x1 5 160 1 Tighten the screw 72002 as far as it will go and then unscrew it a turn The screw must be loose and the diffuser must be movable Item Part number TPL65VA10 30 29 56501 M26x1...

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Page 111: ...aise the alarm and depending on the situation stop the engine Seal the oil leak Soak up oil and dispose of in an environmentally compatible manner Wear safety gloves against thermal risks CAUTION Directives for taking out of operation Serious damage to engine or property can be caused by non compliance with the directives for locking blanking off the turbocharger on the engine Follow the directive...

Page 112: ...evision C Fit cover plate 9 2 NOTICE The cover plate material General structural steel in accordance with DIN EN 10025 2 must be manufactured in house according to the drawing Product B1 B2 B3 B4 B5 B6 B7 B8 TPL65 13 325 30 30 8 10 6 70 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 9 2 Cover plate dimensions mm ...

Page 113: ...g out of operation at short notice 9 Fit cover plate 9 2 Page 111 Copyright 2016 ABB All rights reserved November 2016 HZTL2487_EN Revision C NOTICE Carry out the work as described in the chapter Removal and fitting Remove cartridge group ...

Page 114: ...cover plate 9 2 Page 112 Copyright 2016 ABB All rights reserved November 2016 HZTL2487_EN Revision C Close off opening in gas outlet casing using cover plate Fasten cover plate using spacer sleeves and nuts 61037 CAUTION Shut off the supply of lubricating oil to the turbocharger ...

Page 115: ...e builder s instructions 4 stroke engine with several turbochargers No further measures are necessary on engines with separate air and ex haust gas receivers The engine can be operated as a naturally aspirated engine according to the engine builder s instructions The air line must be closed off at the engine end because the undamaged turbochargers build up a receiver pressure CAUTION The engine ca...

Page 116: ...ght 2016 ABB All rights reserved November 2016 HZTL2487_EN Revision C Blocking the inlets and outlets 9 3 CAUTION Shut off the lubricating oil supply to the turbocharger Shut off compressor casing outlet gas inlet and gas outlet by fitting cover plates NOTICE In this respect refer to the engine manufacturer s instructions 9 3 ...

Page 117: ... November 2016 HZTL2487_EN Revision C Bypass the turbocharger 9 4 CAUTION Shut off the lubricating oil supply to the turbocharger This applies to engines with one turbocharger only The connections are ready and pipes for the bypass are available Fit bypass around turbocharger NOTICE In this respect refer to the engine manufacturer s instructions 9 4 ...

Page 118: ......

Page 119: ...d by preserving oil before taking the engine out of operation and this is circulated by the pre lubrication pump no measures have to be taken Any remaining old engine oil will therefore be flushed away and the bearing sections largely protected against corrosion Mothballing measures WARNING Handling operating materials and supplies Swallowing or inhaling vapours of operating materials and supplies...

Page 120: ...are necessary after taking an engine out of opera tion Dismantle the turbocharger The rotor and the bearing parts must be removed by an official ABB Turbocharging service station and refitted afterwards Clean all parts Machined bright surfaces of steel and cast parts must be oiled with anticorrosive oil Reassemble complete turbocharger Rotor turning in stack draught If the rotor turns as a result ...

Page 121: ... in indi vidual parts See the section Taking out of operation for up to 12 months under Moth balling measures for the measures always necessary when mothballing turbocharger parts If the turbocharger remains mounted on the engine refer to the section Taking out of operation for up to 12 months under Rotating the rotor in stack draught If the entire turbocharger is removed or if the turbocharger is...

Page 122: ......

Page 123: ...es made of leather Wear safety goggles Wear a respiratory mask to protect against particles Wear safety gloves against mechanical risks Disposal must be environmentally compatible professional and in com pliance with locally applicable regulations The turbocharger consists largely of metal cast iron materials steel nickel steel alloys aluminium and bearing brass Further components are Non metallic...

Page 124: ......

Page 125: ...eration in this document please contact an ABB Turbocharging Service Station CAUTION Storage of spare parts All spare parts ordered with the turbocharger must be kept complete and ready for use Parts showing signs of rust should be carefully cleaned and greased Dispose of replaced and unusable parts in a professional and envi ronmentally compatible way Required customer spare part set 97070 Quanti...

Page 126: ...anual TPL65VA10 VA30 Spare parts 12 View of turbocharger with part numbers 12 2 Page 124 Copyright 2016 ABB All rights reserved November 2016 HZTL2487_EN Revision C View of turbocharger with part numbers 12 2 12 2 ...

Page 127: ...customer spare part set Verbus Ripp Washer 61044 in customer spare part set Hexagon head screw 61056 in customer spare part set Hexagon head screw 61057 in customer spare part set Verbus Ripp Washer 61058 in customer spare part set Verbus Ripp Washer 61059 in customer spare part set Hexagon head screw 63000 Turbine diffuser 68000 Foot 72000 Compressor casing 72018 Washer 72029 Stud 72027 Hexagon n...

Page 128: ...ABB Turbo Systems AG Bruggerstrasse 71a CH 5400 Baden Switzerland ABB ...

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