ABB TPL73-B12 Operation Manual Download Page 4

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Operation Manual / TPL73-B.. - 85-B11/ -B12

Table of contents

HZTL2480_EN

Revision D

July 2018

5.3

Changing the filter strip on the filter silencer casing............................................ 59

5.4

Cleaning the compressor during operation ............................................................ 61

5.5

Cleaning turbine blades and nozzle ring in operation ........................................... 67

Troubleshooting.................................................................................................... 80

6.1

Malfunctions when starting....................................................................................... 80

6.2

Surging of the turbocharger....................................................................................... 81

6.3

Malfunctions during operation .................................................................................. 82

6.4

Malfunctions when stopping ...................................................................................... 85

6.5

Speed measurement system ..................................................................................... 86

Removal and installation...................................................................................... 87

7.1

Turbocharger weights.................................................................................................. 87

7.2

Removing the turbocharger........................................................................................ 87

7.3

Installing the turbocharger ........................................................................................ 89

Disassembly and assembly .................................................................................. 90

8.1

Introduction .................................................................................................................. 90

8.2

Module weights ............................................................................................................. 92

8.3

Silencer casing .............................................................................................................. 94

8.4

Removing and installing the filter silencer.............................................................. 99

8.5

Axial clearance ............................................................................................................. 101

8.6

Removing cartridge group ........................................................................................ 102

8.7

Inspection and assessment of valve block ............................................................ 109

8.8

Dismantling and installing the turbine diffuser and nozzle ring ....................... 110

8.9

Installing cartridge group.......................................................................................... 114

8.10

Dismantling and fitting nozzle ring at turbine end .............................................. 122

8.11

Dry-cleaning device..................................................................................................... 126

8.12

Table of tightening torques...................................................................................... 128

Shut-down at short notice ................................................................................. 130

9.1

Possibilities for emergency repair........................................................................... 130

9.2

Locking the rotor......................................................................................................... 131

9.3

Shutting off inlets and outlets ................................................................................. 137

9.4

Bypass the turbocharger ........................................................................................... 137

9.5

Fit cover plate .............................................................................................................. 138

Preserving turbocharger .................................................................................... 142

10.1

Taking out of operation for up to 12 months ........................................................ 142

10.2

Taking out of operation for more than 12 months............................................... 143

Disposing of turbocharger components.......................................................... 144

Spare parts........................................................................................................... 145

12.1

Ordering spare parts .................................................................................................. 145

Summary of Contents for TPL73-B12

Page 1: ...ABB Turbocharging Type TPL73 B12 HT845580 nMmax 333 t Mmax 550 nBmax 316 t Bmax 520 1 s C 03200 35 100 100 Year 2020 Application according to the Operation Manual kg HZTL2480 English TPL73 B12 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: ...ion of 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 Commissioning 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 Admissible air inlet...

Page 4: ... 2 Module weights 92 8 3 Silencer casing 94 8 4 Removing and installing the filter silencer 99 8 5 Axial clearance 101 8 6 Removing cartridge group 102 8 7 Inspection and assessment of valve block 109 8 8 Dismantling and installing the turbine diffuser and nozzle ring 110 8 9 Installing cartridge group 114 8 10 Dismantling and fitting nozzle ring at turbine end 122 8 11 Dry cleaning device 126 8 1...

Page 5: ... Manual TPL73 B 85 B11 B12 Table of contents Copyright 2018 All rights reserved HZTL2480_EN Revision D July 2018 12 2 View of turbocharger with part numbers 148 12 3 View of cartridge group with part numbers 150 ...

Page 6: ... Systems and to use it as intended It provides important information in order that the turbocharger can be operated safely correctly and efficiently This Operation Manual complements and expands existing national reg ulations concerning work safety and accident prevention Target group This Operation Manual is intended for engineers and qualified mechan ics who are responsible for operating the eng...

Page 7: ...HZTL2480_EN Revision D July 2018 1 2 Layout and function 1 Filter silencer 8Nozzle ring 2 Radial plain bearing 9Turbine wheel 3 Thrust bearing 10Bearing casing 4 Bearing bush 11Diffuser 5 Radial plain bearing 12Compressor wheel 6 Gas outlet casing 13Compressor casing 7 Gas inlet casing 14Emergency oil tank Page 5 151 ...

Page 8: ...d 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 routed through the filter silencer 01 to the compressor wheel 12 This air then passes through the diffuser 11 and leaves the turbocharger through the compressor casing 13 The rotor runs in two radial plain bearings 02 05 One plain bearing is in the bearing bush 04 a...

Page 9: ... other pur pose ABB Turbo Systems reserves the right to reject all warranty claims State of the art This turbocharger was built according to state of the art technology and is operationally safe according to recognised safety regulations WARNING Improper operation and maintenance of the turbocharger can result in danger to life and limb of the user or third parties In addition im proper use may ca...

Page 10: ...products are not hazardous in the sense of the Hazardous Sub stances Ordinance Nevertheless the following points are to be ob served when handling VCIs u Ensure good room ventilation u Do not eat drink or keep food at the workplace while working with VCIs u Wear safety gloves u Clean hands and face after working with VCIs u For further information refer to www branopac com Wear safety gloves to pr...

Page 11: ...ng Service Sta tion and repacked u Inspect the package for damage If the package is damaged the tur bocharger or cartridge group must be inspected by an ABB Tur bocharging Service Station and repacked After every 3 years the following work steps must be performed by an ABB Turbocharging Service Station Inspect the components Exchange the desiccant agent Repackage the components NOTICE Replacement ...

Page 12: ... and wearing of personal protective equipment NOTICE The manner in which personnel work on and with the turbocharger with regard to safety and risks is to be checked on a regular basis in accord ance with the Operation Manual u The turbocharger must be shut down immediately in the event of modifications affecting safety or of corresponding operating beha viour by stopping the engine The fault shou...

Page 13: ...ence of personnel The turbocharger must only be operated and serviced by trained and au thorised personnel Basic mechanical training is a prerequisite Design variants This document is valid for different design variants of turbochargers There may be sections and descriptions of components that are not rel evant for a specific turbocharger variant ABB Turbocharging Service Stations will be happy to...

Page 14: ...duct Definition of mandatory signs Mandatory signs show the protective equipment to be worn for a task The mandatory signs are described in chapter Safety and must be com plied with Definition of caution warning The caution and warning signs are described in the chapter Safety ABB Turbo Systems In this document ABB Turbo Systems Ltd is abbreviated to ABB Turbo Systems Official ABB Turbo Systems Se...

Page 15: ... agreed with the enginebuilder 02 Turbocharger operating limits during operation Recommended replace ment intervals for tur bocharger components 03 Replacement interval for plain bearings in 1000 h 04 Replacement interval for compressor in 1000 h 05 Replacement interval for turbine in 1000 h Further information 06 Part number for customer 07 Designation of special design 08 Turbocharger weight in ...

Page 16: ...d tMmax normally 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 wi...

Page 17: ...nce 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 ...

Page 18: ...ar protection 2 4 Definition of Safety instructions The following symbols and terms used in this manual concern safety or refer to possible hazards WARNING Definition of warning Serious personal injuries and even accidents with fatal consequences may occur if work and operating instructions marked with this symbol and the word WARNING are either not followed or not followed pre cisely u Warning si...

Page 19: ...ning plates that must be observed are attached to the turbocharger The warning plates must always be present in the intended locations and must be legible Part number Size mm Product 81080 105 x 74 TPL 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 17 151 ...

Page 20: ... on the turbocharger if you are under physical or mental stress u Work only with suitable tools as well as equipment and working ma terials that are in perfect condition u Electric tools must be solidly earthed and connecting cables may not be damaged u Keep the workplace clean clear away loose objects and remove obstacles on the floor u Keep the floor equipment and the turbocharger clean u Have o...

Page 21: ...amage 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 a...

Page 22: ...at the supply of oil is interrupted especially with an external oil supply u Put the engine into operation only after all parts have been refitted properly CAUTION Mechanical work on the turbocharger Possible damage to or destruction of components on the turbocharger u Perform only those tasks that are described in this manual u Perform work only for which training has been carried out Safety when...

Page 23: ...bocharger 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 ha...

Page 24: ...e 85 dB A always wear ear protection Wear ear protection Hazards due to hot surfaces and substances During operation turbocharger surfaces and attached parts as well as operating materials lubricating oil become hot The surface temperat ure is dependent on the effectiveness of the insulation being used The temperature can become high enough so that it falls into ranges where burns are possible WAR...

Page 25: ...charger 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 eas...

Page 26: ...ntamination 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 adequate...

Page 27: ... area u Take particular care when removing old insulating materials u Dispose of insulating materials properly and in an environmentally compatible way in accordance with applicable local regulations Wear safety goggles Wear a respiratory mask to protect against dusts Wear safety gloves to protect against chemical hazards u Use only suitable non combustible insulating materials u Ensure that the w...

Page 28: ...els 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 no...

Page 29: ...e loading u Fasten turbocharger assemblies components as described in re spective handling steps u Before attaching slings allow turbocharger components to cool down maximum 80 C u Use suitable protection at sharp edges u Completely screw in assembly fitting devices without fail so that they cannot work loose during use u Use assembly fitting devices only for applications described u Make sure rem...

Page 30: ...nditions is an important prerequisite for trouble free turbocharger operation The turbocharger is normally lubricated with oil from the engine oil cir cuit NOTICE With regard to the oil supply please observe the engine builder s spe cifications for lubricating oil selection oil change intervals oil filtration oil pressure and oil temperature Oil filtration A lubricating oil filter with a mesh size...

Page 31: ...6 Temporarily permissible 1h alarm 0 6 0 8 Permissible oil pressure range for normal opera tion 0 8 2 5 Permissible oil pressure range during engine warm up phase 0 8 4 0 Separate lubricating sys tem Kinetic viscosity 12 170 cSt Oil pressure bar Impermissible oil pressure range emergency shutdown without time lag 0 0 0 9 Temporarily permissible 1h alarm 0 9 1 1 Permissible oil pressure range for n...

Page 32: ...t 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 must be monitored ac cording to the current regulatio...

Page 33: ...Contaminated oil Particles of dirt and solid matter in the oil can cause serious damage to the machine or property u During initial commissioning and after all service work the complete lubricating system must be flushed thoroughly with warm oil u When running in the engine and after all service work on the lubricat ing system special running in filters must be used u Check oil pressure in oil sup...

Page 34: ...s temperature in front of and behind turbine u Measure air temperature in front of and behind compressor The measured values must be compared with the values in the accept ance test report while taking different operating conditions into ac count NOTICE Lubricants and pastes used during assembly of the turbocharger li quefy or vaporise and might escape as an oily liquid in the first few hours afte...

Page 35: ...duct before gas inlet and after gas outlet u Inspect exhaust gas duct line in front of and after turbine for any combustion deposits foreign matter or residual water Clean and re move u Inspect air supply line or filter silencer for any foreign matter Clean and remove u Start up turbocharger oil circulation system at engine end u Prepare turbocharger for operation as instructed in section Inspec t...

Page 36: ...rbocharger 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...

Page 37: ...Copyright 2018 All rights reserved HZTL2480_EN Revision D July 2018 Suggestion for noise insulation of the bellows 01 Compressor casing 04 Insulation pads 02 Bellows 05 Insulation mat at least 15 mm 03 Charge air duct scavenging air line 06 Sheet metal cover Page 35 151 ...

Page 38: ... out too late can lead to excessive contamination and wear as well as operating failures u Carry out service work at specified time intervals CAUTION Shortened service intervals Despite observance of the service intervals unusual loads such as sev eral start stops a day harsh environmental factors poor fuel quality or heavy installation vibration can lead to premature machine damage u A shortened ...

Page 39: ...g work Copyright 2018 All rights reserved HZTL2480_EN Revision D July 2018 CAUTION Unknown changes during operation The consequences can range from an impairment to a breakdown u Have unknown causes clarified by an ABB Turbocharging service sta tion Page 37 151 ...

Page 40: ...acturer 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 3 3 Servicing work according to ...

Page 41: ...bine blades using a bore scope for any contamination or damage Optionally this inspection can be carried out after removing the gas inlet casing u Refit the compressor casing internal part u Refit the filter silencer 4 3 5 Service work every 36000 hours Service work on the rotor and bearing parts must be carried out by an ABB Turbocharging Service Station Damaged and worn out parts must be replace...

Page 42: ...These intervals can be found on the turbocharger rating plate Non rotating components Depending on the system specific operating conditions a distinction is made between the replacement interval for the bearing parts and the replacement interval for those non rotating components that are exposed to hot gases Decisive in this respect are various influencing parameters which can drastically shorten ...

Page 43: ...er cover ring 25000 50000 Other casings 100000 Hose ball valve turbine dry cleaning 18000 36000 HFO heavy fuel oil Recommended replace ment intervals h Rotor components See the data on the rating plate Bearings See the data on the rating plate NOTICE Information about replacement intervals The specified values are only guide values and not guaranteed They can vary significantly due for example to ...

Page 44: ...ing system permits continuous monitoring of the tur bocharger speed CAUTION Do not use cables as a climbing aid If you pull the speed measurement cables too hard contacts can be pulled out u Do not tension the speed measurement cables Part number Description 42047 Screw plug 86505 Speed sensor 86515 Cable connector for 86505 86526 F I converter 86528 Tachometer Page 42 151 ...

Page 45: ...wing steps must be carried out u Reduce engine performance immediately until the highest turbochar ger speed no longer exceeds 70 of nBmax u If the engine cannot be stopped continue to run at this reduced en gine performance or turbocharger speed u If the turbocharger surges continuously engine performance must be reduced further u Measure the temperatures in the air and gas lines to and from the ...

Page 46: ...stop the engine u Switch off the lubricating oil supply to the turbocharger u Disconnect the cable connector from the speed sensor u Screw out defective speed sensor u Screw in a new speed sensor to the stop u Observe the tightening torque see the table of tightening torques in the chapter entitled Disassembly and assembly NOTICE Sealing of the speed sensor The speed sensor is designed with a seal...

Page 47: ...silencer can cause a loss of pres sure A significant pressure loss indicates an increase in dirt build up in the filter material 4 6 1 U tube manometer on filter silencer if present 81000 Filter silencer 81050 U tube manometer A mm H2O Pressure loss Pressure difference With a clean filter silencer and clean filter mat if provided the max imum pressure loss A is 120 mm H2O at full load When the pre...

Page 48: ...ration and imme diate repair is not possible the turbocharger can be operated without an emergency oil supply until a repair is possible u Remove pipe leading from valve unit or branch to tank u Fit blind flange to valve unit or branch u Close opening on tank to prevent oil from escaping CAUTION Operation without an emergency oil supply is possible without risk as long as the lubricating system fu...

Page 49: ...switching of the flaps During automatic flap control there is a risk of the turbocharger rotat ing opposite the intended direction of rotation if the air outlet flap is open further than the gas inlet flap during the switching process This can lead to damage on the turbocharger u The turbocharger should only be switched on or off below charging pressures of 0 3 bar u Close the compressor outlet fl...

Page 50: ...th closed flaps To limit the deposits of dirt when operating with closed flaps we re commend you open them at least every 500 hours of operation 4 9 Stopping the engine CAUTION Before shutting down the engine it must be allowed to idle for about 3 minutes longer so that the circulating lubricating oil can take away heat from the turbocharger bearings Page 48 151 ...

Page 51: ...checks and clean ing to ensure that the turbocharger and its attached units function trouble free The external condition and how dirty the cleaning points specified in this chapter are must be established by visual checks at the spe cified intervals The safety precautions must be observed during all maintenance and servicing work The cleaning points described in the following are Filter silencer C...

Page 52: ...n D July 2018 5 2 Cleaning the filter silencer 5 2 1 Filter silencer with tension band 81265 Filter ring if provided 81266 Cover grid 81270 Tension band 81136 Absorption segment 81271 Lock 81137 Sheet metal covering 81268 Connecting strip 81135 Filter silencer body E Insert unit absorption segment sheet metal covering fitted Page 50 151 ...

Page 53: ...tension bands 81270 at the locks 81271 and remove them along with the cover grids 81266 and connecting strips 81268 NOTICE If the cleaning medium vessel is attached to the filter silencer option depends on type of turbocharger the water injection pipe must first be removed at one insert unit E see also the following section Disas sembling the cleaning pipe u Pull out insert units E bend open sheet...

Page 54: ...he insert units E into the slot guides in the filter silencer body 81135 NOTICE If the cleaning medium vessel is attached to the filter silencer option depends on type of turbocharger the water injection pipe must first be removed at one insert unit E see also the following section Disas sembling the cleaning pipe u Fit cover grids 81266 and connecting strips 81268 on the filter si lencer body 811...

Page 55: ...ved HZTL2480_EN Revision D July 2018 5 2 2 Filter silencer and connecting rod 81265Filter ring if provided 81136Absorption segment 81269Connecting rods 81137Sheet metal covering 81266Cover grid 81135Filter silencer body 81272Screw 81273Lock nut EInsert unit absorption segment sheet metal covering fitted Page 53 151 ...

Page 56: ...3 u Loosen and remove screws 81272 to the connecting rods 81269 u Remove connecting rods 81269 u Carefully remove cover grids 81266 NOTICE If the cleaning medium vessel is attached to the filter silencer option depends on type of turbocharger the water injection pipe must first be removed at one insert unit E see also the following section Disas sembling the cleaning pipe u Pull out insert units E...

Page 57: ... now be reattached See also following section entitled Fitting cleaning pipe u Uniformly place the cover grids 81266 in the correct position u Push the connecting rods 81269 through the lugs of the cover grids 81266 CAUTION If the connecting rods 81269 are not correctly positioned in their re cesses on the filter silencer body 81135 the cover grid 81266 can twist and shift There is then a risk of ...

Page 58: ...Cleaning the filter silencer Copyright 2018 All rights reserved HZTL2480_EN Revision D July 2018 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 ring 81265 Page 56 151 ...

Page 59: ...pyright 2018 All rights reserved HZTL2480_EN Revision D July 2018 5 2 3 Removing installing the cleaning line Disassembling the cleaning pipe u Disconnect feed pipe 02 from injection pipe 01 and remove pipe connector from feed pipe u Withdraw feed pipe 02 from guide tube 03 Page 57 151 ...

Page 60: ...e u Hammer guide tube 03 free from peen fixing using a bolt diameter 16 mm and withdraw it Replace damaged parts of the complete cleaning pipe with original parts from ABB Turbo Systems Fitting complete cleaning pipe u Refit guide tube 03 and peen fix it after putting insert units E in place u Fit feed pipe 02 and screw onto injection pipe 01 using connector Page 58 151 ...

Page 61: ...served HZTL2480_EN Revision D July 2018 5 3 Changing the filter strip on the filter silencer casing This chapter is only applicable to turbochargers with a filter silencer cas ing The filter strip 81265 is replaced when a filter silencer is fitted u Dismantle the circumferential part 9 u Open the lock for the filter strip 81265 Page 59 151 ...

Page 62: ...sion D July 2018 u Secure a new filter strip 81265 so that it overlaps the filter strip be ing replaced u Pull the old filter strip until the new filter strip is wound completely around filter silencer u Loosen the connection between the new and old filter strips u Fasten the newly fitted filter strip 81265 and then refit the circum ferential part 9 Page 60 151 ...

Page 63: ...w channels if salt oil mist exhaust gas or dust are sucked in with the air Consequences of contamination Impaired compressor efficiency Higher exhaust gas temperatures Increased fuel consumption Increased rotor unbalance Periodic cleaning of the compressor during operation prevents or delays any major increase in contamination It does not however replace the regular service work during which the t...

Page 64: ...ont of the compressor wheel through an injection pipe fitted in the fil ter silencer 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...

Page 65: ...ine load 25 85 w If the engine compartment temperature is less than 0 C during wet cleaning of the compressor precautionary measures must be taken to prevent ice formation u Start cleaning cycle according to following description 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 comp...

Page 66: ... 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 tu...

Page 67: ...t be met w Engine load 25 85 w If the engine compartment temperature is less than 0 C during wet cleaning of the compressor precautionary measures must be taken to prevent ice formation u Start cleaning cycle according to following description Wet cleaning operation with XC4 Procedure for compressor wet cleaning with XC4 01Cleaning medium vessel 02Pipe 03Injection pipe 04Cleaning instructions 05Co...

Page 68: ...about 3 minutes u Close valve 06 and check that all water has been sucked out u After cleaning wait at least 5 minutes with engine running to allow turbocharger to dry 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 turb...

Page 69: ...ance Experience in operation has shown that despite periodic cleaning during operation it is impossible to dispense with overhauls during which the turbine and nozzle ring are mechanically cleaned However if cleaning is performed correctly and the cleaning system is properly dimensioned the intervals between overhauls can be extended Wet cleaning interval The interval between periodic cleaning is ...

Page 70: ...dry cleaning using dry solid matter in granulate form dirty depos its are removed mechanically by the grains impacting the surface NOTICE Wet and dry cleaning are equally effective However it may be useful to apply both methods together Components at the turbine end are not cleaned until the engine has been started or the engine load reduced The exhaust gas temperature must not exceed the value sp...

Page 71: ... cylinder and exhaust valve rises Operating state prerequisites for wet cleaning In order to be able to carry out a satisfactory cleaning process that has been tested and is recommended by ABB Turbo Systems the following prerequisites must be met w After an engine start up or during operation the engine performance level must be adjusted until the scavenging air pressure pscav is within the range ...

Page 72: ...on nozzle 7a or 10 minutes injec tion nozzle 7b at constant engine output u Check whether the exhaust gas temperature decreases following the turbine u Close regulating valve 2 u Set drain cock 9 in drain pipe 8 on gas outlet casing to Position 2 to keep drain pipe clean using air from compressor casing 21 u Disconnect water supply 1 to regulating valve 2 u After cleaning wait with engine running ...

Page 73: ...low out of the drain pipe de pending on the engine load This flow might not start for 2 3 minutes or it might not occur at all If the drainage of the gas outlet casing is omitted the turbocharger speed and or the gas inlet temperature must be monitored during the cleaning process If the load is too low water can collect in the gas outlet casing Signs of this are a sudden significant drop in tur bo...

Page 74: ... thick dirt deposits and must therefore be carried out more often see chapter Cleaning turbine blades and nozzle ring in operation Operating state prerequisites for integrated dry cleaning device In order to carry out a successful cleaning procedure that has been tested and is recommended by ABB Turbo Systems the following pre requisite must be met w Engine load 25 85 u Start the cleaning cycle ac...

Page 75: ...cleaning device 01 Granulate container 51502 07 Combined air valve Pressure re lief valve 51504 02 Cover cap 51503 08 Clamp 51515 03 Compressed air supply 4 to 10 bar 09 Pipe elbow 51521 04 Hose 51512 10 Heat protection hose 51516 05 On Off valve 51505 11 Screw insert 51514 06 Ball valve 51513 12 Cleaning instructions 51517 CAUTION The air system must be protected against overpressure 10 bar Page ...

Page 76: ...ine u Close the On Off valve 05 u Close the ball valve 06 u Set combined air valve pressure relief valve 07 to pressure relief position u Check whether the exhaust gas temperature after the turbine has de creased NOTICE In order to optimise cleaning it is important that the specified amount of granulate get blown in for each cleaning operation The drain openings in the gas outlet casing must remai...

Page 77: ...able for dry cleaning hard granulated materials such as natural core granulates Soft blast media activated carbon particles The average grain size of the cleaning granulate must be 1 2 2 0 mm The specific weight of the cleaning granulate must not exceed 1 2 kg dm3 Amount of granulate per turbocharger litres TPL73 B TPL77 B TPL80 B TPL85 B 1 0 1 5 2 0 3 0 NOTICE The cleaning granulate must be store...

Page 78: ...g system a non integrated dry cleaning device can be installed in front of the gas inlet casing by the en gine manufacturer Operating state prerequisites for non integrated dry cleaning device In order to carry out a successful cleaning procedure that has been tested and is recommended by ABB Turbo Systems the following pre requisite must be met w Engine load 25 85 u Start the cleaning cycle accor...

Page 79: ...2480_EN Revision D July 2018 Operating non integrated dry cleaning device 01Cover cap G2 06Strap to secure container 02Possible copper gasket 07Safety valve with vent 03Double nipple G2 08Compressed air shut off valve 04Copper gasket 09Compressed air line inner diameter 8 mm 05Plug cock or slide valve G1 10Compressed air maximum 6 bar Page 77 151 ...

Page 80: ... 3 minutes u Close plug cock slide valve 05 u Open safety valve with ventilation 07 to blow out the exhaust gases u Carefully open cover cap 01 of granulate container u Pour specified amount of granulate into granulate container u Firmly close the cover cap 01 u Close safety valve with ventilation 07 u Open compressed air shut off valve 08 u Open the plug cock or slide valve 05 for 3 4 minutes u C...

Page 81: ...ry 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 for the non integrated dry cleaning device NOTICE The choice of material is done according to the section Integrated dry cleaning of the turbine and nozzle ring during operation Amount of granul...

Page 82: ...r Rotor unbalance Contact an ABB Turbocharging Service Station Damaged turbine or com pressor Damaged bearing Rubbing of rotating parts Normal behaviour no malfunction Turbochar ger Minor uniform wear around the periphery of rotor components caused by slight local rubbing of adjacent components is per missible The compressor blades and turbine blades are then shortened somewhat Certain tolerances ...

Page 83: ...c surging Possible damage to components such as the compressor wheel tur bine blades bearings and filter silencer u Have the cause clarified immediately by an ABB Turbocharging ser vice station and rectified u Have components inspected for damage and if necessary replaced by an ABB Turbocharging service station Sporadic surge blows Surging of the turbocharger can occur during certain operating con...

Page 84: ...isplay wrong Replace the manometer Turbochar ger Rotor axial clearance too large Contact an ABB Turbocharging Service Station Reduction in speed Possible causes Elimination Turbochar ger Heavy contamination in the tur bine Clean it Damaged rotor components or bearing Contact ABB Turbocharging Service Station Lines Defects such as leaks in the ex haust gas pipes or charge air ducts Repair them Incr...

Page 85: ...rvation 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...

Page 86: ...e manometer Line to manometer leaking Repair the leak Contaminated filter silencer causing excessive loss of pres sure Clean it Compressor turbine contam inated Damaged compressor tur bine Contact an ABB Turbocharging Service Station Exhaust counterpressure too high Clean or repair the boiler or ex haust silencer Charge air pressure too high Engine performance and engine speed unchanged air intake...

Page 87: ...own Possible causes Elimination Turbochar ger Turbocharger contaminated Clean it Damaged bearing Contact an ABB Turbocharging Service Station Rubbing rotor Foreign object in turbocharger Run down time too short Possible causes Elimination Turbochar ger Turbocharger contaminated Clean it Damaged bearing Contact an ABB Turbocharging Service Station Rubbing rotor Foreign object in turbocharger Page 8...

Page 88: ...b lems for the evaluation electronics This problem is eliminated by removing the gasket Defective sensor Contact ABB Turbocharging service sta tion Measured speeds too high Dirty sensor tip The sensor tip is magnetic and can thus at tract metal particles As a result the dis tance to the auxiliary bearing decreases which can lead to amplification of the noise component and consequently to faulty tr...

Page 89: ...ordance with engine builder s instructions CAUTION Oil orifice plates An orifice plate for adjusting the oil pressure is fitted in each of the two oil inlet channels in the bearing casing When the cartridge group the bearing casing or the turbocharger is fitted to the engine it must be ensured that the orifice plates that are specified for the turbocharger have been installed in the two oil inlet ...

Page 90: ...ly 2018 u Unscrew fixing screws in foot u Lift turbocharger off engine and put it down to one side WARNING If the support for the turbocharger is not provided or unsuitable the turbocharger could tip over during installation and removal work and cause serious or fatal injuries u Support turbocharger at a suitable point u Cover oil connection Page 88 151 ...

Page 91: ...ates An orifice plate for adjusting the oil pressure is fitted in each of the two oil inlet channels in the bearing casing When the cartridge group the bearing casing or the turbocharger is fitted to the engine it must be ensured that the orifice plates that are specified for the turbocharger have been installed in the two oil inlet channels u Check correct installation of oil orifice plates u Ada...

Page 92: ...bed in this chapter u Mark the casing position for assembly Identifying assembly devices Not all assembly devices are marked with a part number They can be identified using the tool list This list is enclosed in the toolbox WARNING Maintaining assembly devices Assembly devices must be checked for damage before and after use u Visually check for corrosion cracks deformation and wear u Don t use dam...

Page 93: ...rgers assemblies or individual components only to lifting gear which is in technically perfect condition and has suffi cient load capacity u Make sure the load is suspended properly on the crane hook u Do not let anyone stand beneath a suspended load Wear safety gloves to protect against mechanical hazards Wear safety helmet Definition of terms Suspension point Defined load attachment point on a c...

Page 94: ...ed off to the next highest value Weights kg Item Description TPL B 73 77 80 85 1 Filter silencer 250 410 580 960 2 Compressor casing internal part 150 260 360 550 3 Wall insert 140 280 430 850 4 Diffuser 60 80 130 230 5 Compressor casing external part 290 480 680 1150 6 Cartridge group with emer gency oil tank 660 1050 1600 2800 7 Turbine diffuser 75 150 250 460 8 Nozzle ring 25 45 65 95 9 Radial ...

Page 95: ...rved HZTL2480_EN Revision D July 2018 Compressor casing internal part assembly Weights kg TPL73 B TPL77 B TPL80 B TPL85 B 350 620 930 1630 NOTICE The total weight of the complete internal part of the compressor casing includes the internal part of the compressor casing the diffuser and the wall insert Page 93 151 ...

Page 96: ...y of the silencer casing This section is applicable only to turbochargers with a filter silencer casing Only the assembly of the silencer casing is described in detail Its disassembly is carried out in the reverse order of its assembly Item Description Item Description 1 2 Bottom part 5 6 9 Circumferential part 3 4 7 8 Side part 10 11 Flange Part number Complete silencer casing 81500 Page 94 151 ...

Page 97: ... may be tightened only when assembly work is finished Only then is it possible for all parts to be fitted u Do not tighten screws during assembly u Fit bottom part 1 to filter silencer using screws A and B NOTICE Screw A The position of screw A serves as a reference for correct fitting of the silencer casing u Before removal of bottom part 1 mark position of screw A u Fit all remaining screws on b...

Page 98: ...2018 All rights reserved HZTL2480_EN Revision D July 2018 u Fit bottom part 2 to filter silencer using screws u Fit side parts 3 and 4 to filter silencer and to bottom part 1 using screws u Fit side parts 7 and 8 to filter silencer to bottom part 2 and to side parts 3 4 using screws Page 96 151 ...

Page 99: ...g Copyright 2018 All rights reserved HZTL2480_EN Revision D July 2018 u Insert flanges 10 and 11 from the side between side parts and fit screws u Fit circumferential part 5 using screws u Fit circumferential part 6 using screws u Fit circumferential part 9 using screws Page 97 151 ...

Page 100: ...rques Nm Screws for fastening individual parts to the filter silencer Screws for fastening indi vidual parts M10 30 M8 25 u Tighten all screws of bottom parts 1 and 2 u Tighten all screws of side parts 3 4 7 and 8 and flanges 10 and 11 u Tighten all screws of circumferential parts 5 6 and 9 Compensator u Fit bellows C to silencer casing using frame F screws S and nuts N Page 98 151 ...

Page 101: ... 4 Removing and installing the filter silencer Removing filter silencer u Remove insulation where necessary u Pass lifting gear through rib on filter silencer and through eyelets at rear u Unscrew nuts 74027 and remove them together with washers 74018 u Remove filter silencer and it set down to one side Fitting the filter silencer u Fit filter silencer in reverse order Page 99 151 ...

Page 102: ...en cer TPL77 91 B u Remove insulation where necessary u Secure the shackle 90195 to a rib fin on the filter silencer u Pass the lifting gear through the eyelets on the back side u Unscrew the nuts 74027 and remove them together with the wash ers 74018 u Remove the filter silencer and it set down to one side Installing the filter silen cer u Install the filter silencer in the reverse order Page 100...

Page 103: ...njury u Wear safety gloves Wear safety gloves to protect against mechanical hazards u Screw on at least four nuts 74027 along with washers 74018 equally spaced around the circumference and tighten them to secure the partition wall axially u Measure and note the axial clearance A CAUTION If the axial clearance A is out of tolerance an ABB Turbocharging Ser vice Station must be contacted Axial clear...

Page 104: ...rtridge group the bearing casing or the turbocharger is fitted to the engine it must be ensured that the orifice plates that are specified for the turbocharger have been installed in the two oil inlet channels u Check correct installation of oil orifice plates CAUTION Locked safety segments 76080 during disassembly Observe the maximum tightening torque for the nuts 90458 so as not to shear off the...

Page 105: ...4000 and can be removed Removing the compressor casing internal part u Unscrew nuts 74027 and remove them together with washers 74018 u Remove six studs 74026 74029 from the upper section and screw in four guide studs 90320 u Leave two holes free for lifting device 90190 u Using press off screws 90900 press off the compressor casing in ternal part 76000 until the lifting device 90190 with shackle ...

Page 106: ... and the diffuser 79000 down on the support angle and an underlay u Remove the O ring 76040 u Loop the lifting device around the rear of the flange F u Carefully rotate the compressor casing internal part with wall insert and diffuser over the support bracket 90025 and set it down with the front side of the flange F on the underlay WARNING Make sure that the underlay does not slip u Rest the compr...

Page 107: ...s reserved HZTL2480_EN Revision D July 2018 Removing the diffuser u Remove screws 76002 u Loop lifting gear around diffuser 79000 and remove diffuser u Carefully press off the wall insert 77000 using the press off screws 90900 and remove it using the swivel lifting eye 90230 u Remove O rings 77005 77006 Page 105 151 ...

Page 108: ...Revision D July 2018 Removing the compressor casing external part u Fasten the lifting device 90190 with shackle 90195 to the com pressor casing external part 74000 and secure it to the crane u Unscrew and remove nuts 61037 u Push apart the compressor casing external part uniformly using the press off nuts 61090 and remove it Page 106 151 ...

Page 109: ...ogether with their washers 61058 u Attach separate lifting gear to each of two ribs on the bearing casing 42001 provided for this purpose NOTICE To correct the slight inclined position of the cartridge group when it is suspended from the rope a piece of square timber must be jammed between the rope and the mounting of the emergency oil tank Use only a square timber and not an iron bar otherwise th...

Page 110: ...d the casing may be damaged u Check that the blades do not rub on the turbine diffuser 63000 by rotating the rotor u Withdraw cartridge group u Remove screws 42064 together with flange 42044 Also remove possible contamination behind the flange u Cover the oil connections Fitting supports for cart ridge group If provided u Unscrew hexagon head screws 42241 and remove valve block 42230 u Attach supp...

Page 111: ...sessment of valve block If provided 1 Valve flap 2 O ring 42234 3 Valve seat On the removed valve block 42230 u Check for free movement of valve flap 1 u Check valve seat 3 using finger u If necessary replace O ring seal 2 NOTICE If scratches are found on the valve seat or the valve flap jams the valve block should be replaced If in doubt contact an ABB Turbocharging Service Station Page 109 151 ...

Page 112: ...tling and installing the turbine diffuser and nozzle ring CAUTION The nozzle ring 56001 must be secured to prevent it from falling be fore pulling out the turbine diffuser 63000 The nozzle ring just hangs loosely on the positioning pins u Before disassembling the turbine diffuser 63000 the nozzle ring 56001 must be secured to prevent it from falling down by using a clamping set and a wooden block ...

Page 113: ...ved HZTL2480_EN Revision D July 2018 u Place the clamp 90921 over the stud 61036 until the clamp is lying flat against the inner radius of the gas outlet casing u Insert the extension A of the torque spanner B through the hole in the clamp and loosen the screws 61056 one after another u Do not yet remove the screws 61056 and Verbus Ripp washers 61057 Page 111 151 ...

Page 114: ... the guide studs 90320 and fit the studs 61036 u Screw nuts 61037 onto the first few threads of the stud 61036 for protection 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 touching the nut 61037 u Loop the lifting gear around the turbine diffuser 63000 and secure...

Page 115: ...outlet casing On the TPL85 raise the holder 90490 with the lifting gear and secure it u Pull the nozzle ring 56001 forwards attach it to the lifting gear and remove it Installing the turbine dif fuser and nozzle ring u Coat the screw threads with high temperature grease u Install the nozzle ring and turbine diffuser in the reverse order of re moval u Align the positioning pins in the nozzle ring w...

Page 116: ...oil inlet channels in the bearing casing When the cartridge group the bearing casing or the turbocharger is fitted to the engine it must be ensured that the orifice plates that are specified for the turbocharger have been installed in the two oil inlet channels u Check correct installation of oil orifice plates Removing supports for cartridge group u Remove cover from oil connection u Fit flange 4...

Page 117: ... If the turbine blades on the rotor have insufficient or no clearance the blades and the casing may be damaged u Check that the blades do not rub on the turbine diffuser 63000 by rotating the rotor u Uniformly tighten the screws 61059 together with Verbus Ripp washers 61058 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...

Page 118: ...ng external part 74000 and secure to a crane u Screw the press off nuts 61090 evenly distributed around the cir cumference of the bearing casing onto the studs up to the end of the thread u Fit the compressor casing external part 74000 and secure with nuts 61037 u Secure the press off nuts 61090 against the compressor casing 74000 by tightening them to the appropriate torque see Table of tightenin...

Page 119: ... lifting eyes 90230 and attach lifting gear u Align the wall insert 77000 with the threaded holes in the com pressor casing internal part 76000 using the dog points at the swivel lifting eyes 90230 and lower it u Loop the lifting gear around the diffuser 79000 align it with the holes and lower it into position u Tighten the screws 76002 as far as possible and then back them off turn The screw must...

Page 120: ...d HZTL2480_EN Revision D July 2018 Compressor casing in ternal part u Secure the lifting device 90190 and the shackle 90195 to the rear of the flange F u Carefully rotate the compressor casing internal part 76000 with wall insert 77000 and diffuser 79000 about the support angle 90025 and set it down on the underlay Page 118 151 ...

Page 121: ...the compressor casing internal part 76000 u Fit O ring 76040 u Remove the support angle 90025 u Fit four guide studs 90320 u Carefully position the compressor casing internal part 76000 with wall insert and diffuser over the guide studs move it in and then re move the lifting device 90190 90195 u Move in the compressor casing internal part as far as it will go u Remove the guide studs 90320 and fi...

Page 122: ...Fit four nuts 74027 complete with washers 74018 equally spaced around circumference and tighten u Loosen the nuts 90458 on the threaded studs of the three securing segments 76080 on the compressor casing internal part 76000 The compressor casing internal part 76000 is now secure relative to the compressor casing external part 74000 NOTICE Note control dimension s The safety segments 76080 are agai...

Page 123: ...note the axial clearance A CAUTION If the axial clearance A is out of tolerance an ABB Turbocharging Ser vice Station must be contacted Axial clearance A mm TPL73 B TPL77 B TPL80 B TPL85 B 0 40 0 58 0 43 0 64 0 46 0 69 0 54 0 79 u Remove four nuts 74027 together with washers 74018 Installing filter silencer u Mount filter silencer and secure with nuts 74027 complete with washers 74018 See section ...

Page 124: ...oop lifting gear through lugs of gas inlet casing If present u Remove two hexagon head screws 61044 and Verbus Ripp washers 61043 from the bottom section and replace them with two studs 90177 u Screw hexagon nuts 90178 onto studs to secure u Unscrew and remove remaining flange screws u Withdraw the gas inlet casing 51001 with nozzle ring 56001 far enough out of the gas outlet casing 61001 for the ...

Page 125: ... with high temperature grease u Fit nozzle ring 56001 and tighten down holder 90175 using screw 61044 u Fit gas inlet casing 51001 and secure by screwing hexagon nuts 90178 onto studs 90177 u Remove holder 90175 and screw 61044 u Fit the gas inlet casing with nozzle ring to the gas outlet casing 61001 u Fit and tighten the hexagon head screws 61044 and Verbus Ripp washers 61043 u Remove the hexago...

Page 126: ...d stud 51086 becomes loose when the nut 51087 is re moved after disassembling the gas outlet casing it must be screwed back into the gas inlet casing hand tight as far as it will go If the nut 51087 cannot be removed with the maximum admissible re lease torque the nut can be heated or removed using a suitable tool u Treat nuts 51087 with rust remover u Loosen all nuts 51087 crosswise and remove to...

Page 127: ...le ring 56001 using suitable lifting gear Assembly u Coat threaded stud 51086 with high temperature grease screw into gas outlet casing 61001 as far as it will go and tighten hand tight u Fit nozzle ring 56001 and tighten down holder 90175 using screw 61044 u Fit gas inlet casing 51001 coat hexagon nuts 51087 with high tem perature grease and secure on the threaded studs 51086 u Remove holder 9017...

Page 128: ...nnecting plate 51511 onto the gas outlet casing with hexagon head screws 51520 u Fit the screw insert 51514 onto the gas inlet casing u Fit the straight screw in coupling 51522 on the ball valve 51513 and the pipe elbow 51521 u Fit the pipe elbow 51521 onto the screw insert 51514 u Fit the hose 51512 on the pressure vessel 51501 and on the ball valve 51513 u Fit clamps 51515 on the gas inlet casin...

Page 130: ...ation Manual TPL73 B 85 B11 B12 8 Disassembly and assembly 8 12 Table of tightening torques Copyright 2018 All rights reserved HZTL2480_EN Revision D July 2018 8 12 Table of tightening torques Page 128 151 ...

Page 131: ... washer M18 170 M20 220 M22 300 M24 400 5 61036 74026 74029 M18 80 M20 80 M22 80 M24 80 6a 61056 61059 M18 370 M20 480 M22 480 M24 480 6b 61044 51087 M18 200 M20 280 M22 380 M24 480 7 42059 42064 M16 105 M20 240 M24 240 10 61037 M18 160 M20 210 M22 280 M24 360 11 61090 M18 15 M20 20 M22 30 M24 35 14 86505 M18x1 5 150 M22x1 5 220 21 90458 M10 30 1 Screw in the screw 76002 as far as it will go and t...

Page 132: ... Soak up oil and dispose of in an environmentally compatible manner Wear safety gloves to protect against thermal hazards CAUTION Directives for taking out of operation Serious damage to engine or property can be caused by non compli ance with the directives for locking blanking off the turbocharger on the engine u Follow the directives of the enginebuilder If the diesel engine must be capable of ...

Page 133: ...n lubricating oil supply without fail during engine operation with locked tur bocharger See section Further information about operation with locked rotor on 2 stroke engines u Shut off oil supply in event of lubricating oil leaking from turbochar ger CAUTION Checking for unbalance Serious damage to machines and property can result from excessive vi bration and unbalance values that are too high u ...

Page 134: ...re the intermediate rings the spacer ring and the adapter ring are fitted correctly All parts must be kept clean and free from grease Table of tools Part number Description 74027 Hexagon nut 90020 Locking device 90442 94006 94007 94008 Hexagon head screw 94001 94002 Intermediate ring 94003 Locking flange 94004 Adapter ring 94005 Clamp 94031 Spacer ring 94032 Washer The locking flange 94003 must be...

Page 135: ...nual TPL73 B 85 B11 B12 9 Shut down at short notice 9 2 Locking the rotor Copyright 2018 All rights reserved HZTL2480_EN Revision D July 2018 TPL73 B Compressor type CV11 Compressor type CV12 CV13 CV14 Page 133 151 ...

Page 136: ... TPL73 B 85 B11 B12 9 Shut down at short notice 9 2 Locking the rotor Copyright 2018 All rights reserved HZTL2480_EN Revision D July 2018 TPL77 B TPL80 B Compressor type CV11 Compressor type CV12 CV13 CV14 Page 134 151 ...

Page 137: ...ce 9 2 Locking the rotor Copyright 2018 All rights reserved HZTL2480_EN Revision D July 2018 TPL85 B11 B12 If possible use the longer hexagon head screws 94008 when fitting the locking flange 94003 Compressor type CV11 Compressor type CV12 CV13 CV16 Page 135 151 ...

Page 138: ...t be removed and the air line at the engine end closed off because the undamaged turbochargers develop a receiver pressure u The operating limit of the engine can be raised by additionally closing off the gas inlet because the exhaust gas is then used to drive the un damaged turbochargers In addition the load on and the temperature of the blocked rotor are reduced If the gas inlet cannot be closed...

Page 139: ...d common air as well as exhaust gas receivers u Shut off compressor casing outlet gas inlet and gas outlet by fitting cover plates NOTICE In this respect refer to the engine manufacturer s instructions 9 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 ...

Page 140: ...9 5 Fit cover plate Copyright 2018 All rights reserved HZTL2480_EN Revision D July 2018 9 5 Fit 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 Page 138 151 ...

Page 141: ... B12 9 Shut down at short notice 9 5 Fit cover plate Copyright 2018 All rights reserved HZTL2480_EN Revision D July 2018 NOTICE Carry out the work as described in the chapter Removal and fitting u Remove cartridge group Page 139 151 ...

Page 142: ...over plate Copyright 2018 All rights reserved HZTL2480_EN Revision D July 2018 u Close off opening in gas outlet casing using cover plate u Fasten cover plate using spacer sleeves and nuts 61037 CAUTION Shut off the supply of lubricating oil to the turbocharger Page 140 151 ...

Page 143: ... the manufacturer s instructions 2 stroke engine with several turbochargers u Block air line on engine side as undamaged turbochargers develop a receiver pressure u Significantly raise operating limit of engine by blocking the gas inlet additionally as exhaust gas is then used to drive undamaged tur bocharger CAUTION Attention must be paid to the speed of the undamaged turbochargers in all cases T...

Page 144: ...and this is circulated by the prelubrica tion pump no measures have to be taken Any remaining old engine oil will thus be flushed away and the bearing sections largely protec ted against corrosion Mothballing measures If the total acid number TAN is greater than 2 mg KOH g the following mothballing measures are necessary after taking an engine out of opera tion u Remove turbocharger u Rotor and be...

Page 145: ...tion 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 Rotating the rotor in stack draught If the entire turbocharger is removed or if the turbocharger is re as sembled next to the engine using the individual pa...

Page 146: ...espiratory mask to protect against dusts Wear safety gloves to protect against mechanical hazards Disposal must be environmentally compatible professional and in com pliance with locally applicable regulations The turbocharger consists largely of metal cast iron materials steel nickel steel alloys aluminium and bearing brass Further components are Non metallic materials filter components of felt a...

Page 147: ... 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 Customer spare part set 97071 for service work every 18000 h TPL73 B TPL85 B Quanti...

Page 148: ...pp washer 42058 42063 15 Hexagon head screw 61044 61056 61059 15 Verbus Ripp washer 61043 61057 61058 3 Hex nut 61037 1 Gasket 42041 2 Gasket 42045 2 O ring 42012 76040 2 O ring 77005 77006 1 O ring 86506 TPL77 B TPL85 B Quantity Description Part number 15 Hexagon head screw 42059 42064 61044 61056 61059 15 Verbus Ripp washer 42058 42063 61043 61057 61058 3 Hex nut 61037 1 Gasket 42041 1 Gasket 42...

Page 150: ... Manual TPL73 B 85 B11 B12 12 Spare parts 12 2 View of turbocharger with part numbers Copyright 2018 All rights reserved HZTL2480_EN Revision D July 2018 12 2 View of turbocharger with part numbers Page 148 151 ...

Page 151: ...er spare part set Hexagon nut 61044 61043 in customer spare part set Hexagon bolt Verbus Ripp washer 61056 61057 in customer spare part set Hexagon bolt Verbus Ripp washer 61059 61058 in customer spare part set Hexagon bolt Verbus Ripp washer 63000 Turbine diffuser 68000 Foot 74000 Compressor casing external part 76000 Compressor casing internal part 76040 in customer spare part set O ring 76080 S...

Page 152: ...nual TPL73 B 85 B11 B12 12 Spare parts 12 3 View of cartridge group with part numbers Copyright 2018 All rights reserved HZTL2480_EN Revision D July 2018 12 3 View of cartridge group with part numbers Page 150 151 ...

Page 153: ...05 Floating disc 32106 Axial bearing 32107 Bearing bush 42001 Bearing casing 42002 Hood 42011 TPL80 B TPL85 B O ring 42012 in customer spare part set O ring 42015 Sealing cover 42041 in customer spare part set Gasket 42045 in customer spare part set Gasket 42059 42058 in customer spare part set Hexagon head screw Verbus Ripp washer 42064 42063 in customer spare part set Hexagon head screw Verbus R...

Page 154: ...ABB Switzerland Ltd Turbocharging Bruggerstrasse 71a CH 5401 Baden Switzerland ...

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