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Operation Manual / TPL85-B14/-B15/-B16

Preliminary remarks

1

Turbocharger rating plate

1.7

Page 14

© Copyright 2016 ABB. All rights reserved.

M

ay

2016

H

ZT

L2491_

EN

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ev

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ion

B

Turbocharger rating plate

1.7

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

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

ginebuilder.

02 Turbocharger operating limits during operation

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

06    Part number for customer
07    Designation of special design
08    Turbocharger weight in kg
09    Turbocharger type
10    Serial number
11    Year of turbocharger construction

1.7

Operating limits

Recommended replace-

ment intervals for turbo-

charger components

Further information

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Summary of Contents for TPL85-B14

Page 1: ...Systems Ltd CH 5401 Baden Type TPL85 B14 HT842305 nMmax 203 t Mmax 550 nBmax 193 t Bmax 520 1 s C 12000 36 100 100 Year 2016 made in Switzerland Application according to the Operation Manual kg HZTL2491 English TPL85 B14 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: ...e 1 8 Contact information 2 Safety 2 1 Introduction 2 2 CE conformity 2 3 Definition of mandatory signs 2 4 Definition of Safety instructions 2 5 Warning plates on the turbocharger 2 6 Safe operation and maintenance 2 7 Hazards during operation and maintenance 2 8 Periodic checking of the pressure vessel 2 9 Lifting loads 3 Start up 3 1 Oil supply 3 2 Inspection work 3 3 Commissioning after taking...

Page 4: ...ration 6 4 Malfunctions when stopping 6 5 Speed measurement system 7 Removal and installation 7 1 Turbocharger weights 7 2 Remove the turbocharger 7 3 Installing the turbocharger 8 Disassembly and assembly 8 1 Introduction 8 2 Module weights 8 3 Silencer casing 8 4 Removing and installing the filter silencer 8 5 Axial clearance 8 6 Removing internal part of compressor casing 8 7 Removing gas inlet...

Page 5: ...491_EN Revision B 10 Storing turbocharger 10 1 Taking out of operation for up to 12 months 10 2 Taking 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 12 3 View of cartridge group with part numbers ...

Page 6: ......

Page 7: ...urbo 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 the...

Page 8: ... ABB All rights reserved May 2016 HZTL2491_EN Revision B Layout and function 1 2 1 Filter silencer 7 Nozzle ring 2 Radial plain bearing 8 Turbine wheel 3 Thrust bearing 9 Bearing casing 4 Radial plain bearing 10 Diffuser 5 Gas outlet casing 11 Compressor wheel 6 Gas inlet casing 12 Compressor casing 1 2 ...

Page 9: ...g 5 The air which is required for operation of the diesel engine and com pressed in the turbocharger is drawn through the filter silencer 1 into the compressor wheel 11 This air then passes through the diffuser 10 and leaves the turbocharger through the compressor casing 12 The rotor runs in two radial plain bearings 2 4 which are located in the bearing casing 9 between the compressor and the turb...

Page 10: ...y claims This turbocharger was built according to state of the art technology and is operationally safe according to recognised safety regulations WARNING Improper operation and maintenance of the turbocharger can result in danger to life and limb of the user or third parties In addition improper use may cause damage to the machine The machine may be operated only by trained personnel Use of the t...

Page 11: ... 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 safet...

Page 12: ... 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 13: ...lso 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 be...

Page 14: ...orresponding 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 Se...

Page 15: ...e 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 System...

Page 16: ...ise agreed with the en ginebuilder 02 Turbocharger operating limits during operation 03 Replacement interval for plain bearings in 1000 h 04 Replacement interval for compressor in 1000 h 05 Replacement interval for turbine in 1000 h 06 Part number for customer 07 Designation of special design 08 Turbocharger weight in kg 09 Turbocharger type 10 Serial number 11 Year of turbocharger construction 1 ...

Page 17: ...hat 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 compon...

Page 18: ...ts reserved May 2016 HZTL2491_EN Revision B Contact information 1 8 Contact information Contact information for the official service stations of ABB Turbo Systems is available online Scan the QR code to access our website ABB Turbo Systems Ltd Bruggerstrasse 71a CH 5401 Baden Switzerland www abb com turbocharging 1 8 ...

Page 19: ...sed 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 ens...

Page 20: ...ection 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 b...

Page 21: ...ttached 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 responsibilit...

Page 22: ...eral 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 th...

Page 23: ... 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 detergents...

Page 24: ...e 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 thi...

Page 25: ...perate 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 Mec...

Page 26: ... dependent on the effectiveness of the insulation being used The tem perature can become high enough so that it falls into ranges where burns are possible WARNING Risk of burning Touching hot surfaces or contact with hot operating materials can lead to serious burns Do not touch hot surfaces and heed the warning plate on the turbo charger Wear heat resistant safety gloves and protective clothing A...

Page 27: ...the skin Ensure good ventilation Observe details in the safety data sheets of the operating and auxil iary materials Observe local laws Wear safety goggles Wear safety gloves against chemical risks Wear a respiratory mask to protect against gases WARNING Risk of fire explosion Combustible or easily ignited operating and auxiliary materials can burst into flame or vapours from them can cause explos...

Page 28: ...n environmentally compatible manner in accordance with statutory regulations Hazards when handling insulating materials WARNING Hazards due to insulating materials Dust and fibres from insulating materials can cause damage to health or irritations Unsuitable combustible insulating materials signify a fire hazard Use only suitable non combustible insulating materials Ensure that the work area is we...

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

Page 30: ... 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 31: ...conditions is an important prerequisite for trouble free tur bocharger operation The turbocharger is normally lubricated with oil from the engine oil circuit NOTICE With regard to the oil supply please observe the engine builder s speci fications for lubricating oil selection oil change intervals oil filtration oil pressure and oil temperature Oil filtration A lubricating oil filter with a mesh si...

Page 32: ...ily permissible 1h alarm 0 6 0 8 Permissible oil pressure range for normal operation 0 8 2 5 Permissible oil pressure range during engine warm up phase 0 8 4 0 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 normal operation 1 1 2 5 Permissible oil ...

Page 33: ...ture at the outlet depends mainly on lubricating oil temperature and pressure at the oil inlet engine load and turbocharger speed exhaust gas temperature The maximum permissible oil temperature at the outlet is listed in the fol lowing table The specified oil outlet temperature is to be regarded as an alarm value for turbocharger operation and be monitored in accordance with standard regulations S...

Page 34: ...ilter for cleanliness before commissioning CAUTION Contaminated oil Particles of dirt and solid matter in the oil can cause serious damage to the machine or property During initial commissioning and after all service work the complete lubricating system must be flushed thoroughly with warm oil When running in the engine and after all service work on the lubricat ing system special running in filte...

Page 35: ...erature in front of and behind turbine Measure air temperature in front of and behind compressor The measured values must be compared with the values in the ac ceptance test report while taking different operating conditions into ac count NOTICE Lubricants and pastes used during assembly of the turbocharger liquefy or vaporise and might escape as an oily liquid in the first few hours after commiss...

Page 36: ...uct 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 b...

Page 37: ...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 acoustic...

Page 38: ...Page 36 Copyright 2016 ABB All rights reserved May 2016 HZTL2491_EN Revision B Suggestion for noise insulation of the bellows 01 Compressor casing 04 Insulation pads 02 Bellows 05 Insulation mat at least 15 mm 03 Charge air duct scavenging air line 06 Sheet metal cover ...

Page 39: ...als 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 machine...

Page 40: ... 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 m...

Page 41: ...tamination or damage Optionally this inspection can be carried out after removing the gas in let casing Refit the compressor casing internal part Refit the filter silencer Service work every 36 000 hours The replacement of bearing parts and the inspection and assessment of the rotor must be carried out by an ABB Turbocharging Service Station Remove the filter silencer Clean the filter silencer and...

Page 42: ...ng parts 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...

Page 43: ...00 Other casings 100000 Hose ball valve turbine dry cleaning 18000 36000 HFO heavy fuel oil 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 inadequate servicing frequent emergency shutdowns and the us...

Page 44: ...eed 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 45: ...ed 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 t...

Page 46: ...n 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 the speed sensor The speed sensor is designed with a seali...

Page 47: ...pressure at the filter silencer The measurement can be used for the following purposes To measure the correction factor for calculating the turbocharger effi ciency during the engine acceptance test The use of a filter mat on the filter silencer can cause a loss of pres sure A significant pressure loss indicates an increase in dirt build up in the filter material U tube manometer on filter silence...

Page 48: ... filter mat if provided the maximum pressure loss A is 120 mm H2O at full load When the pressure loss A has reached 200 mm H2O Clean filter silencer NOTICE Reading off pressure loss The measuring rod on the U tube manometer can be withdrawn to the bottom water level so that the pressure differential A can be easily read off The U tube manometer can be read off more easily if slightly coloured wate...

Page 49: ...blowers in operation If switching over results in turbocharger surging a switch over may only be carried out with the engine is stationary until the cause has been eliminated CAUTION Automatic switching of the flaps During automatic flap control there is a risk of the turbocharger rotating opposite the intended direction of rotation if the air outlet flap is open further than the gas inlet flap du...

Page 50: ...t flap and gas inlet flap must be completely open during normal operation During cut out operation the air outlet flap and gas inlet flap must be completely closed NOTICE Contamination with closed flaps To limit the deposits of dirt when operating with closed flaps we rec ommend you open them at least every 500 hours of operation Stopping the engine 4 7 CAUTION Before shutting down the engine it m...

Page 51: ...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 sile...

Page 52: ...16 HZTL2491_EN Revision B Cleaning the filter silencer 5 2 Filter silencer with tension band 81265 Filter strip if provided 81266 Cover grid 81270 Tension band 81136 Absorption segment 81271 Lock 81137 Cover sheet metal 81268 Connecting strip 81135 Filter silencer body E Insert unit absorption segment cover sheet metal fitted 5 2 5 2 1 ...

Page 53: ...70 at locks 81271 and remove together with cover grids 81266 and connecting strips 81268 NOTICE In the case of an insert unit E the water injection line must first be re moved if a cleaning medium vessel is fitted to the filter silencer optional depending on turbocharger type See also following section Removing cleaning pipe Take out insert units E bend open cover sheet metal 81137 and then take o...

Page 54: ...t insert units E into guide grooves in filter silencer body 81135 NOTICE In the case of an insert unit E the water injection line must first be re moved if a cleaning medium vessel is fitted to the filter silencer optional depending on turbocharger type See also following section Removing cleaning pipe Fit cover grids 81266 and connecting strips 81268 to filter silencer body 81135 Run tension band...

Page 55: ...Page 53 Copyright 2016 ABB All rights reserved May 2016 HZTL2491_EN Revision B Removing installing the cleaning line Disassembling the cleaning pipe Disconnect feed pipe 02 from injection pipe 01 and remove pipe connector from feed pipe Withdraw feed pipe 02 from guide tube 03 5 2 2 ...

Page 56: ...r 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 Refit guide tube 03 and peen fix it after putting insert units E in place Fit feed pipe 02 and screw onto injection pipe 01 using connector Punch out guide tube Fitting complete cleaning pipe ...

Page 57: ...l rights reserved May 2016 HZTL2491_EN Revision B Changing the filter strip on the filter silencer casing 5 3 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 Dismantle the circumferential part 9 Open the lock for the filter strip 81265 5 3 ...

Page 58: ...May 2016 HZTL2491_EN Revision B Secure a new filter strip 81265 so that it overlaps the filter strip being replaced Pull the old filter strip until the new filter strip is wound completely around filter silencer Loosen the connection between the new and old filter strips Fasten the newly fitted filter strip 81265 and then refit the circumfer ential part 9 ...

Page 59: ... 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 and...

Page 60: ...mpressor wheel through an injection pipe fitted in the filter silenc er 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 build up of dirt deposits is not too advanced CAUTION Corrosion and deposits when cleaning Damage and impairment of turbocharger parts due to salt water and cooling wat...

Page 61: ...aning procedure which has been tested and is recommended by ABB Turbo Systems the following pre requisite must be met Engine load 25 to 85 Start the cleaning cycle according to following description Wet clean ing procedure 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 plug ...

Page 62: ...er has 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 S...

Page 63: ...cleaning procedure which has been tested and is recommended by ABB Turbo Systems the following pre requisite must be met Engine load 25 to 85 Start the cleaning cycle according to the following description Wet cleaning procedure with XC4 Procedure for compressor wet cleaning with XC4 01 Cleaning medium vessel 02 Pipe 03 Injection pipe 04 Cleaning instructions 05 Cover 06 Valve NOTICE When using th...

Page 64: ...e valve 06 and check that all water has been sucked out After cleaning wait at least 5 minutes with engine running to allow tur bocharger 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 inspect...

Page 65: ...or imbalance Experience in operation has shown that despite periodic cleaning during operation it is impossible to dispense with overhauls during which the tur bine 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 The interval between periodic cleaning is very dependen...

Page 66: ...nd 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 specified in the respective cleaning instructions see section PrerequisitesTPL A C Operating state prerequisites for wet cleaning turbine and noz...

Page 67: ... the engine and the temperature following the engine cylinder and exhaust valve rises Operating state prerequisites for wet cleaning NOTICE In order to be able to carry out a satisfactory cleaning process which has been tested and recommended by ABB Turbo Systems the follow ing prerequisites must be met After an engine start up or during operation the engine performance level must be adjusted unti...

Page 68: ... 2 Before cleaning the Operating state prerequisites for wet cleaning must be met Check that the water supply 1 is open and safeguarded and that it is also connected to the regulating valve 2 before the turbocharger Set drain cock 9 of drain pipe 8 on gas outlet casing to Position 1 and check whether exhaust gas escapes Quickly open regulating valve 2 until manometer 3 indicates follow ing pressur...

Page 69: ... be heard at the turbine end These are caused by the turbine touching the cover ring that shrinks due to cooling This results in a minimal increase in the clearance which however has no effect on the operating safety relia bility When cleaning water must be drained from the gas outlet casing via the drain pipe 8 The exhaust gas temperature following the turbocharger sinks during cleaning by 60 180...

Page 70: ...g 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 NOTICE In order to carry out a successful cleaning procedure which has been tested and is recommended by ABB Turbo Systems the following pre requisite must be met Engine load 25 to 85 Start the cleaning ...

Page 71: ...grated dry cleaning device 01 Granulate container 51502 07 Combined air valve Pressure relief 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...

Page 72: ... 05 Close ball valve 06 Set combined air valve pressure relief valve 07 to pressure relief position 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 remain closed when cleaning the turbine As ...

Page 73: ... are suitable 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 TPL85 B 3 0 NOTICE The cleaning granulate must be stored in a dry and clean location to prevent blockage of the pipes when cle...

Page 74: ... 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 the non integrated dry cleaning device NOTICE In order to carry out a successful cleaning procedure which has been tested and is recommended by ABB Turbo Systems the following pre requisite must be met Engine load 25 to 85 Start the cleaning c...

Page 75: ...ed May 2016 HZTL2491_EN Revision B Operating non integrated dry cleaning device 01 Cover cap G2 06 Strap to secure container 02 Possible copper gasket 07 Safety valve with vent 03 Double nipple G2 08 Compressed air shut off valve 04 Copper gasket 09 Compressed air line inner diameter 8 mm 05 Plug cock or slide valve G1 10 Compressed air maximum 6 bar ...

Page 76: ...ount of granulate into granulate container Firmly close the cover cap 01 Close safety valve with ventilation 07 Open compressed air shut off valve 08 Open the plug cock or slide valve 05 for 3 4 minutes Close plug cock or slide valve 05 Close compressed air shut off valve 08 Open safety valve with ventilation 07 Check whether the exhaust gas temperature after the turbine has decreased NOTICE In or...

Page 77: ...6 ABB All rights reserved May 2016 HZTL2491_EN Revision B Cleaning parameters for non integrated dry cleaning device NOTICE The choice of material takes place according to chapter Integrated dry cleaning of turbine and nozzle ring during operation Product Amount of granulate dm3 TPL85 B 3 0 Amount of granulate per turbocharger ...

Page 78: ......

Page 79: ... 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 tole...

Page 80: ... 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 operat...

Page 81: ...ometer display wrong Replace the manometer Turbo charger Rotor axial clearance too large Contact an ABB Turbocharging Service Station Reduction in speed Possible causes Elimination Turbo charger 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 t...

Page 82: ...r it or contact the manufac turer Turbocharger Air starvation for example filter silencer clogged with dirt Clean it Compressor turbine conta minated 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 83: ...g Replace the manometer Line to manometer leaking Repair the leak Contaminated filter silencer causing excessive loss of pres sure Clean it Compressor turbine contami nated 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 84: ...ing 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 turbocharg...

Page 85: ...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 fa...

Page 86: ......

Page 87: ...91_EN Revision B Removal and installation Turbocharger weights 7 1 Lifting gear with a sufficient load limit must be used for removing and in stalling the turbocharger The following weight specification is the heaviest possibility This guide value can differ from data on the rating plate de pending on the specification TPL85 B 12000 7 7 1 Weight kg ...

Page 88: ... 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 cable connector on speed sensor Remove insulating shell from bearing casing Fast...

Page 89: ... 87 Copyright 2016 ABB All rights reserved May 2016 HZTL2491_EN Revision B WARNING If support for the turbocharger is missing or defective when setting it aside the turbocharger could tip over and cause serious or even fatal injuries Support turbocharger at a suitable point Cover oil connection ...

Page 90: ...n 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 in foot in acc...

Page 91: ...itions 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 c...

Page 92: ...tach 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 componen...

Page 93: ...hts 8 2 The specified weights of individual parts or assemblies are guides round ed off to the next highest value Item Description TPL85 B 1 Filter silencer 960 2 Compressor casing internal part 550 3 Wall insert 850 4 Diffuser 230 5 Compressor casing external part 1200 6 Cartridge group 3000 7 Cover ring 150 8 Nozzle ring 95 9 Radial gas inlet casing 500 8 2 Weights kg ...

Page 94: ...right 2016 ABB All rights reserved May 2016 HZTL2491_EN Revision B Compressor casing internal part assembly TPL85 B 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 Weight kg ...

Page 95: ...y assembly of the silencer casing This section is applicable only to turbochargers with a filter silencer cas ing 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 Complete silencer casing 81500 8 3 Part number...

Page 96: ...r casing screws may be tightened only when assembly work is finished Only then is it possible for all parts to be fitted Do not tighten screws during assembly 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 Before removal of bottom part 1 mark position of screw A Fit all remaining scre...

Page 97: ... Copyright 2016 ABB All rights reserved May 2016 HZTL2491_EN Revision B Fit bottom part 2 to filter silencer using screws Fit side parts 3 and 4 to filter silencer and to bottom part 1 using screws Fit side parts 7 and 8 to filter silencer to bottom part 2 and to side parts 3 4 using screws ...

Page 98: ...g 8 3 Page 96 Copyright 2016 ABB All rights reserved May 2016 HZTL2491_EN Revision B Insert flanges 10 and 11 from the side between side parts and fit screws Fit circumferential part 5 using screws Fit circumferential part 6 using screws Fit circumferential part 9 using screws ...

Page 99: ...s Screws for fastening individual parts to the filter silencer Screws for fastening individual parts M10 30 M8 25 Tighten all screws of bottom parts 1 and 2 Tighten all screws of side parts 3 4 7 and 8 and flanges 10 and 11 Tighten all screws of circumferential parts 5 6 and 9 Compensator Fit bellows C to silencer casing using frame F screws S and nuts N Tightening torques Nm ...

Page 100: ...ter silencer 8 4 Remove insulation where necessary Secure the shackle 90195 to a rib fin on the filter silencer Pass the lifting gear through the eyelets on the back side Unscrew the nuts 74027 and remove them together with the washers 74018 Remove the filter silencer and it set down to one side Install the filter silencer in the reverse order 8 4 Removing the filter silenc er TPL77 91 B Installin...

Page 101: ...essor wheel has sharp edges which can result in injury Wear safety gloves Wear safety gloves against mechanical risks 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 Measure and note the axial clearance A TPL85 B 0 54 0 79 CAUTION If the axial clearance A is out of tolerance an ABB Turbochargin...

Page 102: ... of the safety segments 76080 Fit four nuts 74027 complete with washers 74018 equally spaced around circumference and tighten Take nuts 90458 out of the toolbox and screw them onto threaded studs of three safety segments 76080 in the compressor casing in ternal part 76000 Tighten the nuts 90458 to a maximum torque of 30 Nm NOTICE Note the control dimension u Dimension TPL85 B u 27 6 The compressor...

Page 103: ...shackle 90195 and the lifting gear Using press off screws 90900 press away the compressor casing in ternal part 76000 until the lifting device 90190 can be attached and secured to a crane Remove the compressor casing internal part 76000 along with the wall insert and diffuser Fit the support angle 90025 Remove the O ring 76040 Set down the compressor casing internal part 76000 along with the wall ...

Page 104: ...th shackles 90195 Slightly raise the compressor casing internal part 76000 along with the wall insert and diffuser using the lifting device 90190 Use a second set of lifting gear to carefully move the compressor cas ing internal part 76000 into a vertical position Set down the casing with the flange F on an underlay WARNING Make sure that the underlay does not slip Allow the compressor casing inte...

Page 105: ...opyright 2016 ABB All rights reserved May 2016 HZTL2491_EN Revision B Remove screws 76002 Loop lifting gear around diffuser 79000 and remove diffuser Carefully press off the wall insert 77000 using the press off screws 90900 and remove it using the swivel lifting eye 90230 Remove O rings 77005 77006 Removing the diffuser ...

Page 106: ...g 8 7 Remove insulation from gas inlet casing 51001 Loop lifting gear through eylet lugs on gas inlet casing Undo screws 61044 and remove gas inlet casing 51001 complete with nozzle ring 56001 Remove screws 56014 sleeves 56013 and nozzle ring 56001 Undo and remove screws 57005 Fit two guide studs 90320 Press away cover ring 51085 using press off screws 90901 and remove over guide studs 90907 8 7 ...

Page 107: ... ring 51085 with the position of the gas outlet flange Make certain to install the cover ring in the correct position Coat the screw threads with high temperature grease Screw in and tighten the screws 57005 Remove the guide studs 90320 Mount the nozzle ring 56001 on the gas inlet casing 51001 using the screws 56014 and sleeves 56013 Fit gas inlet casing 51001 complete with nozzle ring to gas outl...

Page 108: ...r and fit swivel lifting eyes 90230 Align wall insert 77000 with threaded holes in internal part 76000 of compressor casing using dog points on swivel lifting eyes 90230 and then lower it Loop lifting gear around diffuser 79000 align it with holes and put down into position Tighten screws 76002 as far as they will go and then back them off a turn Leave screws loose and diffuser moveable Fasten lif...

Page 109: ...casing is suspended only from lifting device 90190 Remove support angle 90025 together with shackle 90195 Fit O ring 76040 to internal part 76000 of compressor casing Fit guide studs 90320 Carefully insert internal part 76000 of compressor casing complete with wall insert and diffuser over guide studs 90320 into external part of compressor casing 74000 Remove lifting device 90190 90195 Insert inte...

Page 110: ...0 is not guaranteed Fit four nuts 74027 complete with washers 74018 equally spaced around circumference and tighten Unscrew the nuts 90458 on threaded studs of three safety 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...

Page 111: ...st mechanical risks Measure and note the axial clearance A TPL85 B 0 54 0 79 CAUTION If the axial clearance A is out of tolerance an ABB Turbocharging Ser vice Station must be contacted Unscrew nuts 74027 and remove them together with washers 74018 Fit the filter silencer and fasten it using the nuts 74027 and the washers 74018 see the section Removing and installing the filter silencer Connect al...

Page 112: ...Mount the connecting plate 51511 onto the gas outlet casing with hexagon head screws 51520 Fit the screw insert 51514 onto the gas inlet casing Fit the straight screw in coupling 51522 on the ball valve 51513 and the pipe elbow 51521 Fit the pipe elbow 51521 onto the screw insert 51514 Fit the hose 51512 on the pressure vessel 51501 and on the ball valve 51513 Fit clamps 51515 on the gas inlet cas...

Page 113: ...Operation Manual TPL85 B14 B15 B16 Disassembly and assembly 8 Dry cleaning device 8 10 Page 111 Copyright 2016 ABB All rights reserved May 2016 HZTL2491_EN Revision B ...

Page 114: ...tion Manual TPL85 B14 B15 B16 Disassembly and assembly 8 Table of tightening torques 8 11 Page 112 Copyright 2016 ABB All rights reserved May 2016 HZTL2491_EN Revision B Table of tightening torques 8 11 8 11 ...

Page 115: ...ion B Item Part number TPL85 B 1 82005 M16 x 1 5 45 31 76002 M20 4 74027 with washer M24 400 5 74026 74029 M24 80 6 61044 M24 480 7 42059 42064 M12 110 14 86505 M22 x 1 5 220 15 56014 M16 160 16 57005 M16 160 18 90458 M12 30 1 Screw in the screw 76002 as far as it will go and then back it off turn The screw must be loose and the diffuser moveable Tightening torques Nm ...

Page 116: ......

Page 117: ...p the engine Seal oil leaks Soak up oil and dispose of in an environmentally compatible manner Wear safety gloves against thermal risks CAUTION Directives for taking out of operation Serious damage to engine or property can be caused by non compliance with the directives for locking blanking off the turbocharger on the engine Follow the directives of the enginebuilder If the diesel engine must be ...

Page 118: ...and switch on lubricating oil supply without fail during engine operation with locked turbocharger See section Further information about operation with locked rotor on 2 stroke engines Shut off oil supply in event of lubricating oil leaking from turbo charger CAUTION Checking for unbalance Serious damage to machines and property can result from excessive vibration and unbalance values that are too...

Page 119: ...ing illustrations Make sure the intermediate rings the spacer ring and the adapter ring are fitted correctly All parts must be kept clean and free from grease Part number Description 74027 Hexagon nut 90020 Locking device 90920 Press off tool with screw 94001 94002 Intermediate ring 94003 Locking flange 94004 Adapter ring 94006 94008 Hexagon head screw 94031 Spacer ring 94032 Washer The locking fl...

Page 120: ...85 B14 B15 B16 Short term turbocharger shut down 9 Locking the rotor 9 2 Page 118 Copyright 2016 ABB All rights reserved May 2016 HZTL2491_EN Revision B TPL85 B14 B15 B16 Compressor type CV11 Compressor type CV12 CV13 CV16 ...

Page 121: ...ndamaged turbochargers develop a receiver pressure 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 off the following operating limits must be observed The pressure in the c...

Page 122: ...urbochargers and common air as well as exhaust gas receivers Shut off compressor casing outlet gas inlet and gas outlet by fitting cover plates NOTICE In this respect refer to the engine manufacturer s instructions Bypass the turbocharger 9 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 th...

Page 123: ...operation and this is circulated by the prelubrication pump no measures have to be taken Any remaining old engine oil will thus be flushed away and the bearing sections largely protected 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 Remove turbocharger Rotor an...

Page 124: ...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 re assembled next to the engine using the in...

Page 125: ...ade 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 mat...

Page 126: ......

Page 127: ...al ABB Turbocharging Service Station If different design versions have not been taken into consideration in this document please contact an ABB Turbocharging Service Station CAUTION Storage of spare parts All spare parts ordered with the turbocharger must be kept complete and ready for use Parts showing signs of rust should be carefully cleaned and greased Dispose of replaced and unusable parts in...

Page 128: ...n Part number 1 Hose 51512 1 Ball valve 51513 1 Screw insert 51514 3 Clamp 51515 1 Heat protection hose 51516 1 Pipe elbow 51521 1 Screw insert 51522 Customer spare part set 97070 for service work every 36000 h Quantity Description Part number 2 O ring 42012 76040 3 Gasket 42041 42069 12 Hexagon head screw 42059 42064 1 Gasket 42045 6 Hexagon head screw 56014 57005 4 Hexagon nut 61037 1 Gasket 610...

Page 129: ...Operation Manual TPL85 B14 B15 B16 Spare parts 12 Ordering spare parts 12 1 Page 127 Copyright 2016 ABB All rights reserved May 2016 HZTL2491_EN Revision B ...

Page 130: ...Manual TPL85 B14 B15 B16 Spare parts 12 View of turbocharger with part numbers 12 2 Page 128 Copyright 2016 ABB All rights reserved May 2016 HZTL2491_EN Revision B View of turbocharger with part numbers 12 2 12 2 ...

Page 131: ...nlet casing 51085 Cover ring 56001 Nozzle ring 61001 Gas outlet casing 61035 Hexagon head screw 61037 in customer spare parts set Hexagon nut 68000 Foot 74000 Compressor casing external part 76000 Compressor casing internal part 76040 in customer spare parts set O ring 76080 Safety segment 77000 Wall insert 77005 in customer spare parts set O ring 77006 in customer spare parts set O ring 79000 Dif...

Page 132: ...ual TPL85 B14 B15 B16 Spare parts 12 View of cartridge group with part numbers 12 3 Page 130 Copyright 2016 ABB All rights reserved May 2016 HZTL2491_EN Revision B View of cartridge group with part numbers 12 3 12 3 ...

Page 133: ...pressor end 32102 Radial bearing at turbine end 32104 Auxiliary bearing 32105 Floating disc 32106 Axial bearing 42001 Bearing casing 42002 Hood 42011 O ring 42012 in customer spare parts set O ring 42015 Sealing cover 42041 in customer spare parts set Gasket 42045 in customer spare parts set Gasket 42059 in customer spare parts set Hexagon head screw 42064 in customer spare parts set Hexagon head ...

Page 134: ...ABB Turbo Systems AG Bruggerstrasse 71a CH 5400 Baden Switzerland ABB ...

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