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Operation Manual / 4 Product description / TPS44-H.. - TPS52-H..

Taking out of operation at short notice

Page 86 / 99

HZTL4037_EN

Revision A

August 2016

10.2

Installing a replacement turbocharger

NOTICE

Quick recommissioning
In order to quickly put an engine back into operation after a turbocharger has

sustained damage, ABB Turbo Systems recommends having a replacement

turbocharger available in storage (see the chapter entitled "Storage of new

turbochargers and spare parts"). The defective turbocharger can be re-

moved and the replacement turbocharger installed within a short period of

time.



Remove defective turbocharger (see chapter

Removing and Installing [➙

11]).



Install replacement turbocharger (see chapter Removing and Installing

[➙

11]).



Send the defective turbocharger to an ABB Turbocharging Service Station for inspection

and repair.

10.3

Installing a replacement cartridge group

WARNING

Incorrect handling of a cartridge group
Incorrect handling of a cartridge group can damage the turbocharger and

cause injuries to persons.



Have repairs to the cartridge group carried out by an ABB Turbocharging

Service Station only.

NOTICE

Quick recommissioning
In order to quickly put an engine back into operation after a turbocharger has

sustained damage, ABB Turbo Systems recommends having a replacement

cartridge group available in storage (see the chapter entitled "Storage of new

turbochargers and spare parts"). The defective cartridge group can be re-

moved and the replacement cartridge group installed within a short period of

time. A replacement cartridge group is ready for use immediately and in-

cludes the complete bearing casing with bearing and a balanced rotor.

The repair of a cartridge group requires special tools and the expertise of an ABB Turbocharg-

ing Service Station. The rotating parts turn very fast and are very sensitive to unbalance.



Remove defective cartridge group (see chapter

Dismantling and fitting [➙

59]).



Install replacement cartridge group (see chapter

Dismantling and fitting [➙

59]).



Send the defective cartridge group to an ABB Turbocharging Service Station for inspection

and repair.

Summary of Contents for TPS48-H33

Page 1: ...arging Operation Manual TPS48 H33 HT566298 English Original Operation Manual Chapter Document ID 1 Introduction HZTL4005_EN_E 2 Safety HZTL4026_EN_B 3 Safety data sheet HT566298 4 Product description HZTL4037_EN_A ...

Page 2: ...als and the corresponding operating limits in chapter 3 are jointly defined with the enginebuilder This information is specific to the product Non observance of the recommended replacement intervals and the operating limits increases the risk of unpre dictable component failures ...

Page 3: ...ents Page 1 8 Copyright 2016 ABB All rights reserved HZTL4005_EN Revision E July 2016 Introduction 1 Introduction 3 1 1 Purpose of the manual 3 1 2 Symbols definitions 4 1 3 Storage of new turbochargers and spare parts 6 1 4 Contact information 8 ...

Page 4: ......

Page 5: ...plains the turbocharger and contains instructions for safe operation The Operation Manual is a complement to and expansion of existing national regulations for occupational safety accident prevention and environmental protection Target group The Operation Manual is aimed at engineers and trained mechanics responsible for the proper operation of the engine and for the turbocharger connected to it A...

Page 6: ...rk 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 Caution and warning signs are described in chapter Safety ABB Turbo Systems ABB Turbo Systems Ltd is identified as ABB Turbo Systems in this document Official service stations of ABB Turbo Sy...

Page 7: ...eaning Pictogram Meaning Tighten with specified torque Affix Tighten over specified tightening angle Measure Hand tight tighten without tools Note Oil Visually inspect Apply screw locking paste e g Loctite Please note text for numbered work step Apply high temperature grease See document Apply other paste in accordance with specifications Dispose of in an environmentally compatible professional wa...

Page 8: ...of the Ordinance on Hazardous Substances Nevertheless the following points must be observed when handling VCI Observe the information in the material safety data sheet Ensure proper space ventilation Do not eat drink or store food at the workplace while working with VCI Clean hands and face after working with VCI For more information see www branopac com Wear safety gloves to protect against mecha...

Page 9: ...y an ABB Turbocharging Service Station Check the package for damage If the package is damaged the turbocharger or cartridge group must be checked and repackaged by an ABB Turbocharging Service Station After every 3 years the following steps must be carried out by an ABB Turbocharging Service Station Checking the component Replacing the desiccant Repackaging the component NOTICE Replacement compone...

Page 10: ...hts reserved HZTL4005_EN Revision E July 2016 1 4 Contact information Contact information of the ABB Turbocharging Service Stations 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 ...

Page 11: ...ed use 5 1 6 Deflagration on gas engines 6 1 7 Warning plates on the turbocharger 6 1 8 Turbocharger rating plate 7 1 9 Periodic check of the pressure vessels 8 1 10 Lifting of loads 9 1 11 Prerequisites for operation and maintenance 10 1 12 Hazards during operation and maintenance 11 1 13 Safe operation 13 1 14 Safe maintenance 14 Copyright 2016 ABB All rights reserved HZTL4026_EN Revision B May ...

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Page 13: ...afety instructions Are a consequence of insufficient or inappropriate performance of maintenance and in spection work The operating company is responsible for defining measures that regulate safe access to and safe handling of the turbocharger All instructions contained in this chapter must be observed for safe and trouble free operation of the turbocharger and during all work on the turbocharger ...

Page 14: ...sonal protective equipment to be worn specific to the respective task 1 4 Definition of safety instructions WARNING Definition of Warning Non compliance or inaccurate compliance with working or operating instruc tions indicated by this symbol and the word WARNING can lead to serious injuries to personnel and even to fatal accidents Warning signs must always be observed CAUTION Definition of Cautio...

Page 15: ...d with a clockwise direction of rotation as viewed from the turbine end The specific operating limits of the turbocharger were determined on the basis of information from the enginebuilder about the intended use These data are given on the rating plate ABB Turbo Systems accepts no liability and rejects all warranty claims for any non intended uses 1 Euromot The European Association of Internal Com...

Page 16: ... the bearing casing must be checked and the bearing casing must be examined to see if it has shifted in relation to the bracket A crack inspection of the casings and the bellows is also recommended The nearest ABB Turbocharging Service Station should be instructed to carry out this inspection and assessment 1 7 Warning plates on the turbocharger Warning plates that must be observed are attached to...

Page 17: ...uring operation Recommended inspection and replacement intervals of turbocharger components 03 Inspection interval of plain bearings in 1000 h 04 Replacement interval of compressor in 1000 h 05 Replacement interval of turbine in 1000 h Further data 06 Customer part number 07 Designation for special design 08 Weight of turbocharger in kg 09 Turbocharger type 10 Serial number 11 Year of construction...

Page 18: ...and replacement intervals increases the risk of unpredictable component failures Locations of the rating plates The locations of the rating plates are defined in the Operation Manual Product description 1 9 Periodic check of the pressure vessels The pressure vessels used by ABB Turbo Systems for example in the wet or dry cleaning process are so called simple pressure vessels The locally applicable...

Page 19: ... on the crane hook Figure 4 Attachment angle If there are two or more suspension points the attachment angle of 45 must not be exceed ed This prevents excessive loading due to diagonal pull Before looping around the components of the turbocharger let them cool down maximum 80 C Attach components of the turbocharger as described in the respective action steps Use a suitable edge guard if there are ...

Page 20: ...ect condi tion Only authorised personnel may remain in the vicinity of the turbocharger when the engine is running Competence of personnel The turbocharger must only be operated and serviced by trained and authorised personnel Basic mechanical training is a prerequisite Modifications to the turbocharger Modifications to the turbocharger must be approved by ABB Turbo Systems Original parts and safe...

Page 21: ... exceeds 85 dB A Wear ear protection Hazards due to hot surfaces Surfaces of the turbocharger attached parts and operating fluids lubricating oil get hot during operation The surface temperature depends on the efficacy of the existing insulation The temperature may rise to a level that can cause burns WARNING Danger of burns Touching hot surfaces or contact with hot operating fluids can cause burn...

Page 22: ...sical hazards Contact with rotating parts can cause severe injury The turbocharger must never be used without the filter silencer or the air suction branch With the engine stopped the rotor can rotate due to the stack draught alone Operate the turbocharger in compliance with the specifications Secure the rotor against unintentional rotation during maintenance Wear safety gloves to protect against ...

Page 23: ...ulation resistance or voltage on the electrical components 1 13 Safe operation Mechanical hazards during operation During standard operation no mechanical hazards are caused by the turbocharger itself if it has been properly installed Safety during commissioning and operation Visually inspect your working environment before starting work Remove any obstacles and objects littering the workplace Che...

Page 24: ... mechanical hazard and risk of fall ing Wear protective clothing WARNING Risk of falling When working on the turbocharger there is a risk of falling Do not climb onto the turbocharger or onto attached parts and do not use them as climbing aids Use suitable climbing aids and working platforms for work above body height Comply with the general accident prevention regulations Only perform work on the...

Page 25: ...or set up service and inspection work and the inspection inter vals Inform the operating staff before starting any service or repair work Make sure the engine is not started while work is being conducted on the turbocharger Before taking off any cover or removing any guard from the turbocharger switch off the engine and wait until the turbocharger has come to a standstill Make sure that the oil su...

Page 26: ... materials and supplies Operating materials and supplies are substances required for the operation of the turbo charger or for the performance of maintenance work Oils greases coolants detergents and solvents acids and similar substances can be classified as hazardous substances WARNING Handling operating materials and supplies Swallowing or inhaling vapours of operating materials and supplies or ...

Page 27: ...plies Comply with local legislation Hazards due to the handling of insulation materials WARNING Danger from insulation materials Dust or fibres from insulation materials can have adverse effects on the health or cause irritations Unsuitable and combustible insulation materials are a fire hazard Only use suitable and non combustible insulation materials Ensure good ventilation at the workplace Avoi...

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Page 29: ...ion Manual TPS48 H33 Safety data sheet Page 1 1 Safety data sheet Copyright 2017 ABB All rights reserved HT566298 January 2017 TPS48 H33 HT566298 TPS48 H33 HT566298 1018 680 996 650 11379956 180 16 60 60 2017 ...

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Page 31: ...moving the turbocharger 12 2 3 Installing the turbocharger 14 3 Commissioning 19 3 1 Oil supply 19 3 2 Inspection procedures 19 3 3 Commissioning after taking out of operation 22 4 Monitoring operation 23 4 1 Oil pressure oil temperature 23 4 2 Exhaust gas temperature before turbine 25 4 3 Turbocharger speed 25 5 Operation and service 29 5 1 Noise emission 29 5 2 Service work 31 5 3 Expected repla...

Page 32: ...he diffuser 74 9 12 Installing the cartridge group 75 9 13 Installing nozzle ring 77 9 14 Fitting the turbine casing 78 9 15 Rotating the turbocharger 79 9 16 Radial clearances N and R 80 9 17 Installing the gas outlet casing 81 9 18 Installing air inlets 82 9 19 Table of tightening torques 83 10 Taking out of operation at short notice 85 10 1 Possible emergency repairs 85 10 2 Installing a replac...

Page 33: ...anual 4 Product description TPS44 H TPS52 H Table of contents Page 3 99 Copyright 2016 ABB All rights reserved HZTL4037_EN Revision A August 2016 13 3 View of turbocharger with part numbers 94 Figures 97 Tables 99 ...

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Page 35: ...tions will be pleased to provide information see Contact information at www abb com turbocharging Accuracy of illustrations The illustrations in this document are general in nature and intended for ease of understand ing Differences in detail are therefore possible 1 2 Registered trademarks The trademarks of outside companies are used in this document These are marked with the symbol 1 3 Related d...

Page 36: ...L4037_EN Revision A August 2016 1 4 Layout and function of the turbocharger Figure 1 Layout and function of the turbocharger 01 Air suction branch filter silencer 06 Plain bearing bush 02 Compressor casing 07 Turbine 03 Diffuser 08 Nozzle ring 04 Bearing casing 09 Turbine casing 05 Axial thrust bearing 10 Compressor wheel ...

Page 37: ...phere through the exhaust gas pipe connected to the turbine casing The compressor wheel 10 sucks in air or a mixture of gas and air through the air suction branch 01 or the filter silencer In the compressor wheel 10 the energy required for building up the pressure is transferred to the air By flowing through the diffuser 03 and the compres sor casing 02 the air is compressed further and is then di...

Page 38: ...the enginebuilder without insulation must be equipped later with warning plates on the insulation This is the responsibility of the enginebuilder If warning plates are not present in the designated locations or not readable proceed as fol lows Order new warning plates 72080 from ABB Turbocharging Service Stations see chapter Ordering spare parts 93 Remove any warning plates that have become unread...

Page 39: ... All rights reserved HZTL4037_EN Revision A August 2016 1 6 Position of the rating plate The rating plate 01 is attached at the top on the bearing casing of the turbocharger Explana tions regarding the rating plate can be found in the chapter dealing with safety Figure 3 Position of the rating plate ...

Page 40: ......

Page 41: ...s to the heaviest variant possible Depending on the specification the weight specified on the rating plate may be lower than the standard value specified here Product Weights kg TPS44 120 TPS48 180 TPS52 250 Table 2 Weight of the turbocharger One swivel lifting eye S is required to safely lift this turbocharger This is not included in the ABB Turbo Systems scope of delivery Swivel lifting eye S to...

Page 42: ...ing out any work Wear safety gloves to protect against thermal hazards CAUTION Do not strain cables If you pull the speed measurement cables too hard contacts can be pulled out Do not strain the speed measurement cables by pulling NOTICE Gas outlet casing 61001 The gas outlet casing 61001 can remain fitted in the exhaust gas pipe if the locking to the turbine casing is accessible Otherwise the com...

Page 43: ...5 and secure the rolled up cable on the turbocharger This protects the plug from being crushed 4 Install the swivel lifting eye S and attach the lifting gear to it 5 Lift the turbocharger away from the support vertically 6 Cover the connections Version with water cooling CAUTION Freezing of the cooling water in the bearing casing If cooling water freezes in the bearing casing this can lead to seve...

Page 44: ...ts Gaskets that are forgotten damaged or improperly inserted will lead to oil leaks Always use new gaskets and insert them carefully into the slot The oil is supplied 02 and drained 03 through the bracket 01 The necessary sealing is provided by O rings The O rings are not included in the ABB Turbo Systems scope of delivery Figure 6 Inserting O rings into bracket 01 Bracket 02 Oil supply 03 Oil dra...

Page 45: ... 01 3 Remove nuts 01 again Requirements for the threaded rods 02 Figure 8 Requirements for threaded rods Product Diameter Threaded rod mm Material DIN ISO 898 Part 1 Thread length L1 mm Length of threaded rod L2 mm TPS44 Ø 16 M16 10 9 12 9 30 150 TPS48 Ø 16 M16 10 9 12 9 30 170 TPS52 Ø 20 M20 10 9 12 9 30 195 Table 4 Requirements for threaded rods Fastening material scope of delivery The threaded ...

Page 46: ...g eye S and attach the lifting gear to it 4 Align the turbocharger over the threaded rods of the bracket 5 Place the turbocharger on the bracket 6 Lightly oil the hexagon nuts 7 Fit the hexagon nuts and tighten in accordance with the following section 8 Connect cable to speed sensor 86505 2 3 4 Fastening the turbocharger with a standard nut Tighten the fitted nuts in accordance with the following ...

Page 47: ...6 2 3 5 Connecting the turbocharger Connect all the gas pipes and air lines according to the enginebuilder s instructions If the gas outlet casing from ABB has not been dismantled with the turbocharger refer to chapter Installing the gas outlet casing 81 Version with water cooled bearing casing Fit the water pipes according to the instructions of the enginebuilder ...

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Page 49: ...ebuilder s specifications on the selection of the lubricating oil and the oil change intervals 3 1 2 Pre lubrication Pre lubrication must be carried out as follows Switch on the oil pump Build up oil pressure see Table 6 Do not exceed a pre lubrication time of 2 minutes Start the engine Let the oil pump run until the pump driven by the engine generates sufficient pressure 3 1 3 Oil filtering Lubri...

Page 50: ...n Lubricating system CAUTION Contaminated oil Serious damage to engine or property can be caused by dirt and solid mate rial particles in the oil At initial commissioning and after all service work the complete lubricating system must be thoroughly flushed with warm oil Use special running in filters when running in the engine and after all ser vice work on the lubricating system Check that the oi...

Page 51: ...erature at the inlet Refer to chapter Monitoring operation 23 for admissible values Tightness of pipes Check all the pipes for tightness 3 2 4 Checks when starting up the engine Measure speed oil pressure and charging pressure at various engine performances Measure the exhaust gas temperature before and after the turbine Measure the air temperature before and after the compressor Compare the measu...

Page 52: ... locking screws on the water connections and fit the water pipe General Check the exhaust gas pipe before and after the turbine for combustion residues or water residues and clean it Remove any foreign objects that may be present Check and clean filter silencer or air supply line and remove any foreign objects that may be present Put engine side oil circulation to the turbocharger into operation P...

Page 53: ... signal Not admissible Stop the engine immediately 0 6 Table 6 Lubricating oil pressure oil inlet 01 Turbocharger contact surface 02 Oil inlet 03 Oil outlet M Oil pressure measuring point T Oil temperature measuring point For monitoring the lubricating oil pressure ABB Turbo Systems recommends installing an M manometer immediately before the turbocharger If the pressure is controlled electronicall...

Page 54: ...the outlet The oil temperature at the outlet is mainly dependant on Lubricating oil temperature and pressure at the oil inlet Engine load and turbocharger speed Exhaust gas temperature The maximum admissible oil temperature at the outlet is listed in the following table The spec ified oil outlet temperature is to be considered as alarm value for the turbocharger operation and must be monitored acc...

Page 55: ... 3 Turbocharger speed 4 3 1 Introduction A speed measuring system enables the constant monitoring of the turbocharger speed CAUTION Do not strain cables If you pull the speed measurement cables too hard contacts can be pulled out Do not strain the speed measurement cables by pulling CAUTION Machine damage Operation above the operating limits defined on the rating plate can shorten the recommended ...

Page 56: ...L4037_EN Revision A August 2016 4 3 2 Layout and overview Figure 10 Layout and overview of the speed measurement system 86505 Speed sensor 42188 Screw plug 86515 Cable connector 42189 Gasket 86526 F I converter 01 Plug with integrated voltage limiter 86528 Tachometer Alternative mounting position for speed sensor 32109 Sealing disc ...

Page 57: ...gers does not exceed 70 of nBmax If the engine cannot be stopped it can continue to be driven at this reduced engine load or turbocharger speed If a turbocharger surges continuously the engine performance must be reduced further Measure the temperatures in the air lines and exhaust gas pipes from and to the turbo chargers and compare with normal values Check the pressure loss of the alternative ai...

Page 58: ...sealing lip and an additional O ring and does not need an additional gasket for assembly Figure 11 Fitting the speed sensor Part number TPS44 TPS48 TPS52 86505 M12 x 1 5 15 Nm M12 x 1 5 15 Nm M12 x 1 5 15 Nm Table 9 Tightening torque 86505 Reduce the engine performance to idling and then stop the engine Pay attention to post lubrication Stopping the engine 37 Switch off the lubricating oil supply ...

Page 59: ... is measured at a distance of 1 meter from the turbocharger The highest value of the emission sound pressure level1 reaches a maximum of 105 dB A near the filter silencer The following prerequisites must be fulfilled with regard to the turbo charger to observe this limit value Air inlet system has been fitted All standard noise reducing measures2 have been fitted Bellows at the air outlet has been...

Page 60: ...pyright 2016 ABB All rights reserved HZTL4037_EN Revision A August 2016 Suggestion for noise insulation bellows Figure 12 Noise insulation bellows 01 Compressor casing 02 Bellows 03 Charge air duct scavenging air duct 04 Insulation cushion 05 Insulation mat at least 15 mm 06 Sheet metal cover ...

Page 61: ... or performed too late can cause excessive contamination wear and operating failures Carry out the service work at the specified time intervals CAUTION Shortened service intervals Exceptional stresses such as several starts stops per day harsh environ mental conditions poor fuel quality or high system vibrations can lead to un timely machine damage even if the prescribed service intervals are ob s...

Page 62: ...asured values must be entered every 24 48 hours in the engine logbook of the enginebuilder Performance and speed of the engine Air intake temperature Charging pressure Pressure loss in the charge air cooler Lubricating oil pressure and lubricating oil temperature If present Speed of the turbocharger Air temperature after the compressor and after the charge air cooler Exhaust gas temperature before...

Page 63: ...rvice Station Assembly and disassembly of the cartridge group and assessment of the ro tor and bearing parts requires the specialist knowledge of an ABB Turbo charging Service Station The rotor parts turn very fast and are very sensitive to unbalance The rotor and bearing parts must be checked and assessed by an ABB Turbocharging Service Station The following work can be carried out as preparation...

Page 64: ...on must be made be tween the intervals to be expected for replacing the bearing parts and replacing the non rotating components exposed to hot gas A decisive role is played by various influencing parameters which in extreme cases can dras tically shorten the replacement interval of these parts During the prescribed periodic service work the individual parts are examined for wear and replaced if ne...

Page 65: ...ne values for example due to the following influences Fuel quality and fuel treatment Load profile thermal cycling also number of starts stops emergency shutdowns operat ing point Gas inlet temperature Turbocharger specification System specific operating conditions combustion quality exhaust gas composition For bearing parts Lubricating oil quality oil filtering oil condition oil monitoring Load p...

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Page 67: ...g Observe the oil pressure while performing post lubrication 0 5 poil 1 0 Switch off post lubrication as soon as the rotor has come to a standstill Deviating procedures must be coordinated with ABB Turbo Systems CAUTION Water cooling after stopping the engine If the heat in the turbocharger is not dissipated after the engine stops dam age may result Allow the water cooling of the turbocharger to c...

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Page 69: ...al controls and cleaning operations which are intended to ensure the trouble free functioning of the turbocharger Maintenance interval Maintenance work Operating status Similar to the service interval usually every 8000 12000 h 1 Cleaning components mechanically 40 Engine stopped Table 11 Maintenance table h Hours of operation 1 ABB Turbo Systems recommends having mechanical cleaning carried out b...

Page 70: ...asily sustain mechanical dam age The use of needle descalers for example or other striking tools dam ages the components Depending on the specification nozzle rings or tur bine casings may have protective coatings which can also be damaged Use only soft tools such as rags brushes or wire brushes In case of heavy contamination the cleaning methods described in this chapter such as soaking for examp...

Page 71: ...cer is described in chapter Disassembly and assembly Cleaning the filter ring if present Remove filter ring 81265 Clean filter ring 81265 as required or every 500 hours of operation and replace after the fifth cleaning process at the latest Contamination of the filter ring depends on the degree of purity of the sucked in air Rinse the filter ring 81265 with water and mild detergent or in the case ...

Page 72: ...ion segments 81136 must only be cleaned lightly with compressed air a soft brush or a moist cleaning cloth Have any heavily contaminated absorption segments replaced by an ABB Turbocharging Service Station Fitting the filter silencer see Figure 13 Insert the absorption segments 81136 into the sheet metal coverings 81137 Bend the sheet metal coverings 81137 back to their original shape and insert i...

Page 73: ...ding to the material safe ty data sheet Comply with local legislation Wear safety goggles Wear safety gloves to protect against chemical hazards Wear a respiratory mask to protect against gases The following parts which are relevant in terms of performance can be cleaned in accordance with the description below Figure 14 Cleaning the compressor casing diffuser mechanically 72000 Compressor casing ...

Page 74: ...gloves to protect against chemical hazards Wear a respiratory mask to protect against gases Baked layers of contamination for example from heavy fuel oil or coked oil occur at the tur bine end The following parts which are relevant in terms of performance can be cleaned in accordance with the description below Figure 15 Cleaning the nozzle ring turbine casing mechanically 56001 Nozzle ring 51000 T...

Page 75: ...into operation There can be severe contamination of the compressor wheels due to badly filtered suction air and of the turbines because of heavy fuel oil operation or carbonized oil Cleaning during op eration may not suffice to remove such contamination instead it may need to be cleaned me chanically during standard service intervals see chapter service work Remove turbocharger from engine see cha...

Page 76: ...ntamination penetrates the cartridge group this can impair the function of the turbocharger and damage parts inside the cartridge group Make sure that no water or contamination can enter into the cartridge group Clean the compressor wheel with a rag or soft brush which has been soaked in water with a household cleaning agent Do not use wire brushes Dry the compressor wheel and the gap between the ...

Page 77: ...or cleaning the turbine are described in the following Figure 16 Soaking contamination of the turbine Product A mm B mm C mm TPS44 115 20 155 TPS48 115 29 180 TPS52 135 35 215 Table 12 Dimensions of the cleaning container To soak the layers of dirt on the turbine the cartridge group can be immersed vertically in a container 02 with fluid Set the container 02 inside a larger container 03 so that th...

Page 78: ...group this can impair the function of the turbocharger and damage parts inside the cartridge group Place the cartridge group on suitable supports 01 made of wood or metal Observe value B for the supports 01 so that the cartridge group is not immersed too deeply Let the layers of dirt on the turbine soak for four hours Removing dirt WARNING Health hazard due to soot particles If soot particles ente...

Page 79: ...posits lead to rotor unbal ance This can result in bearing or turbocharger damage Remove all traces of contamination from the turbine After brushing off the dirt fill the container 02 with clean water and not with salt water Immerse the turbine of the cartridge group in clean water so that any loose dirt comes off Lift up the cartridge group and align it horizontally Clamp the partition wall to th...

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Page 81: ...nebuilder Turbocharger Rotor unbalance Contact ABB Turbocharging Service Station Turbine or compressor damaged Bearing damaged Table 14 Malfunctions when starting Vibrations Rotating parts rubbing Normal behaviour not a malfunction Turbocharger A minimal and uniform wear on the circumference of the rotor components is permit ted This wear can be caused by slight local rubbing against adjacent comp...

Page 82: ...oil pressure too low Speed reduces Possible causes Remedy Engine Defect on the connected cylinders in pulse charging Contact enginebuilder Turbocharger Turbine and or nozzle ring severely con taminated Clean see chapter Periodic maintenance work 39 Rotor components or bearing damaged Contact ABB Turbocharging Service Station Pipes Defects such as leaks in the exhaust gas pipes or charge air ducts ...

Page 83: ...er too high Check clean cooling system Insufficient ventilation Improve ventilation Table 19 Malfunctions during operation Exhaust gas temperature too high Charge air pressure too low Engine performance and engine speed unchanged suction condition normal Possible causes Remedy Engine Air receiver not sealed Repair Gas piping between engine and turbine not sealed Injection mistimed Set correctly Va...

Page 84: ...rely contaminated or corroded compressor wheel can reduce the compressor wheel s fatigue endurance limit and result in the turbocharger being damaged Rectify malfunction in accordance with the following table Possible causes Remedy Turbocharger Compressor components severely con taminated by the ventilation gases that have been fed in Clean see chapter Periodic maintenance work 39 Optimize oil sep...

Page 85: ...se clarified and remedied immediately by an ABB Turbo charging Service Station Have parts assessed for damage and if necessary replaced by an ABB Turbocharging Service Station Possible causes Remedy Engine Protective grating in front of the turbo charger contaminated or damaged Clean replace Turbocharger Filter silencer or diffuser contaminated Clean see chapter Periodic maintenance work 39 Heavy ...

Page 86: ...e 25 Malfunctions when stopping Runout noises Runout time too short The runout time must be noted down as a reference Because the runout time depends on the oil viscosity the runout time must always be measured at the same oil temperature If the runout time is significantly shorter in comparison to a previous measurement the follow ing table must be observed Possible causes Remedy Turbocharger Tur...

Page 87: ...g spare parts 93 Replacing the speed sensor 28 Table 27 Malfunction of the speed measurement system No signal or poor signal amplitude Measured speed too high Possible causes Remedy Turbocharger Sensor tip contaminated since it is magnetic and can attract metallic particles This reduces the distance to the signal emitting sealing disc which can lead to amplification of the noise component and henc...

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Page 89: ...ork Wear safety gloves to protect against thermal hazards WARNING Cutting injuries when working on the turbocharger Some parts on the turbocharger may have sharp edges There is a risk of a cutting injury Wear safety gloves against mechanical risks when conducting assembly and disassembly work Wear safety gloves to protect against mechanical hazards CAUTION Further operations This Operation Manual ...

Page 90: ... the surface WARNING Suspended loads Loads that are not attached according to regulations can cause injury to per sonnel or fatal accidents Only fasten the turbocharger assemblies or individual parts on properly functional lifting gear with sufficient load limit Pay attention to the correct attachment of loads on the crane hook People must not stand under suspended loads Wear safety gloves to prot...

Page 91: ... ABB Turbo Systems scope of delivery Swivel lifting eye S to be used Product Thread Length L mm Minimum load limit kg TPS44 M8 13 125 TPS48 M8 13 190 TPS52 M10 18 260 Table 30 Swivel lifting eye S to be used Two ring nuts are required for safer lifting of the cartridge group which are not included in the ABB Turbo Systems scope of delivery Ring nuts to be used VRM Product Thread Starpoint ring nut...

Page 92: ...ts of the individual parts or assemblies are rounded up standard values Figure 17 Overview of assemblies Designation TPS44 TPS48 TPS52 01 Radial air suction branch 5 6 8 02 Axial air suction branch 3 4 4 03 Filter silencer 15 04 Compressor casing 17 30 45 05 Diffuser 2 3 4 06 Cartridge group 24 40 65 07 Nozzle ring 1 2 3 08 Turbine casing 1 inlet 30 45 70 09 Gas outlet casing 16 Table 32 Weights o...

Page 93: ... August 2016 9 3 Removing the gas outlet casing NOTICE Marking casing position for assembly ABB Turbo Systems recommends marking the casing positions prior to dis assembly Figure 18 Removing the gas outlet casing 1 Manually secure the gas outlet casing 61001 2 Loosen and remove screws 51008 3 Remove the gas outlet casing 61001 4 Remove the gasket 52400 ...

Page 94: ... casing position for assembly ABB Turbo Systems recommends marking the casing positions prior to dis assembly Figure 19 Removing the air inlets 1 Manually secure the filter silencer 81000 or air suction branch 82000 2 Loosen and remove V clamp 72020 3 Remove the filter silencer 81000 or air suction branch 82000 4 Remove and dispose of O ring 81010 82010 refer to Disposing of turbocharger com ponen...

Page 95: ...ight 2016 ABB All rights reserved HZTL4037_EN Revision A August 2016 9 5 Removing the compressor casing Figure 20 Removing the compressor casing 1 2 1 Place the turbocharger in a vertical position on a soft underlay 2 Loosen the hexagon head screws 72011 and remove them with fastening strips 72012 ...

Page 96: ... the compressor casing cannot be loosened it can be pressed off against the turbine casing with the press off tool 90042 See section Pressing off the casing 67 Figure 21 Removing the compressor casing 2 2 1 Secure lifting gear to compressor casing 72000 2 Remove the compressor casing 72000 vertically 3 Rotate the compressor casing 72000 through 180 and put it in place 4 Remove and dispose of O rin...

Page 97: ...016 9 6 Pressing off the casing CAUTION Axial force of the press off tool Using the press off tool 90042 a high level of axial force can be generated If the casing is pressed off with too much force on one side the rotor can be damaged Use the tool on both sides in alternation and make sure not to press off too hard on either side Figure 22 Press off the casing ...

Page 98: ...admissible values an oil orifice is mandatory at the oil inlet of the bearing casing if the oil inlet pressure is 3 bar overpressure If an oil orifice is fitted in the oil inlet of the bearing casing it must not be removed Do not loosen screw plugs CAUTION Oil leaks These screw plugs must not be removed for maintenance work If a screw plug is loosened the gasket can be damaged This can result in a...

Page 99: ...Removing the turbine end fastening strips NOTICE Marking casing position for assembly ABB Turbo Systems recommends marking the casing positions prior to dis assembly Figure 24 Removing the cartridge group 1 1 Loosen the hexagon nuts 51007 2 Remove hexagon nuts 51007 Verbus Ripp discs 51003 and fastening strips 51002 3 Screw in the swivel lifting eye S up to the stop ...

Page 100: ... tool If the turbine casing cannot be loosened it can be pressed off against the bearing casing with the press off tool 90042 See section Pressing off the casing 67 Figure 25 Removing cartridge group 2 1 Insert screws from service support into cartridge group 2 Secure ring nuts VRM onto the screws with washers 3 Secure the lifting gear to the ring nuts and swivel lifting eye as shown 4 Remove the ...

Page 101: ...cartridge group and rotate in the horizontal position 2 Remove the lifting gear from the ring nuts 3 Remove the ring nuts VRM and screws from the service support 4 Place the cartridge group onto the fitted service support 90012 5 Fit and hand tighten nuts Measure Axial clearance A and radial clearance B 72 9 8 Removing nozzle ring Figure 27 Removing the nozzle ring 1 Remove the nozzle ring 56001 v...

Page 102: ...moval and before the installation of the cartridge group Attach the dial indicator and align it for the respective clearance as per the illustration Figure 28 Measuring clearance A and B Product A mm B mm TPS44 0 10 0 18 0 69 1 27 TPS48 0 11 0 19 0 86 1 52 TPS52 0 13 0 22 0 98 1 68 Table 33 Permissible clearances A and B 1 Move the rotor to and fro up to the stop For an accurate measurement elevat...

Page 103: ... and the turbine casing 51000 Figure 29 Measuring nozzle ring compression 42001 Bearing casing 51000 Turbine casing 56001 Nozzle ring 1 Measure dimensions A B and C on cleaned surfaces 2 Calculate the compression PD and compare it with the permissible values in the following table Product Compression PD mm TPS44 0 23 0 23 TPS48 0 23 0 23 TPS52 0 24 0 24 Table 34 Permitted nozzle ring compression P...

Page 104: ...ision A August 2016 9 11 Fitting the diffuser Figure 30 Fitting the diffuser Part number TPS44 TPS48 TPS52 72041 M5 5 Nm M5 5 Nm M6 10 Nm Table 35 Tightening torque 72041 1 Position the diffuser 79000 in the compressor casing 72000 2 Rotate the diffuser until its bore is aligned with the bore in the compressor casing 3 Fit and tighten screw 72041 ...

Page 105: ...rotating it by 90 Figure 31 Lifting the cartridge group and rotating it by 90 1 Loosen and remove nuts 2 Lift the cartridge group out of the service support 90012 3 Insert the screws of the service support from above and fit ring nuts VRM with washers 4 Attach lifting gear to the ring nuts VRM 5 Lift cartridge group at the side of the ring nuts VRM and turn it into a vertical position Use edge gua...

Page 106: ...roup Figure 32 Fitting the cartridge group Part number TPS44 TPS48 TPS52 72011 M8 40 Nm M8 40 Nm M10 80 Nm Table 36 Tightening torque 72011 1 Lower cartridge group carefully into the compressor casing 2 Align cartridge group to the marking 3 Place first fastening strip 72012 according to illustration 4 Place remaining fastening strips 72012 5 Fit and tighten hexalobular head screws 72011 ...

Page 107: ...016 9 13 Installing nozzle ring Figure 33 Installing the nozzle ring 1 Fit lamellar sealing ring 56005 in the slot of the nozzle ring When doing this pay atten tion to correct winding of the lamellar sealing ring see detail A 2 Secure the lamellar sealing ring 56005 with adhesive tape 3 Installing the nozzle ring Ensure correct position according to illustration ...

Page 108: ...ne casing Part number TPS44 TPS48 TPS52 51007 M8 30 Nm M8 30 Nm M10 60 Nm Table 37 Tightening torque 51007 1 Coat the threads of the studs 51006 with high temperature grease 2 Turn the turbine casing 51000 by 180 3 Fit two swivel lifting eyes 01 on the turbine casing 4 Place the turbine casing onto the cartridge group 5 Align turbine casing to the marking 6 Fit and tighten the fastening strips 510...

Page 109: ...Revision A August 2016 9 15 Rotating the turbocharger Rotating the turbocharger Figure 35 Rotating the turbocharger 1 Fit swivel lifting eye S 2 Insert screws from the service support 3 Fit ring nuts VRM 4 Attach lifting gear 5 Elevate and rotate the turbocharger 6 Place the turbocharger on a soft underlay Measure Radial clearances N and R 80 ...

Page 110: ...tation Figure 36 Measuring clearances N and R Product N mm R mm TPS44 0 25 0 50 0 40 0 70 TPS48 0 30 0 60 0 50 0 80 TPS52 0 40 0 70 0 60 0 95 Table 38 Permissible clearances N and R 1 Push the feeler gauges 01 into the gap such that there is no clearance The upper direc tion N1 and lower direction N2 must be covered simultaneously 2 Calculate clearance N and compare it with the permissible values ...

Page 111: ...10 50 Nm Table 39 Tightening torque 51101 1 Coat the threads of the hexagon head screws or studs 51008 with high temperature grease 2 Align the casing position of the gas outlet casing 61001 to the marking 3 Fit two hexagon head screws 51008 in the upper area of the gas outlet casing 4 Position the gasket 52400 on the threads of the hexagon head screws 51008 5 Install the gas outlet casing 61001 o...

Page 112: ...S44 TPS48 TPS52 72020 M10 30 Nm M10 30 Nm M10 30 Nm Table 40 Tightening torque 72020 1 Fit the new O ring 81010 82010 to the filter silencer 81000 or the air suction branch 82000 2 Manually position the filter silencer 81000 or the air suction branch 82000 on the com pressor casing 72000 3 Fit the V clamp 72020 4 Align the casing position of the filter silencer 81000 or the air suction branch 8200...

Page 113: ...rved for the designated screw fittings Position Part number TPS44 TPS48 TPS52 01 82007 M18 x 1 5 60 Nm M18 x 1 5 60 Nm M18 x 1 5 60 Nm 02 82005 81005 M16 x 1 5 50 Nm M16 x 1 5 50 Nm M16 x 1 5 50 Nm 03 72020 M10 30 Nm M10 30 Nm M10 30 Nm 04 72041 M5 5 Nm M5 5 Nm M6 10 Nm 05 72011 M8 40 Nm M8 40 Nm M10 80 Nm 06 42188 M12 x 1 5 35 Nm M12 x 1 5 35 Nm M12 x 1 5 35 Nm 07 51007 M8 30 Nm M8 30 Nm M10 60 N...

Page 114: ... August 2016 Position Part number TPS44 TPS48 TPS52 10 61005 M18 x 1 5 60 Nm M18 x 1 5 60 Nm M18 x 1 5 60 Nm 11 86505 M12 x 1 5 15 Nm M12 x 1 5 15 Nm M12 x 1 5 15 Nm 12 90 Nm 90 Nm 90 Nm Table 41 Overview of tightening torques These screw plugs must not be removed for maintenance work If the screw plug is loos ened the tightness is no longer guaranteed ...

Page 115: ...ly 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 compliance with the directives for blanking the turbocharger off the engine Follow the directives of the enginebuilder If the engine has to be operated again as quickly as possible following a turbocharger defect then th...

Page 116: ...orrect handling of a cartridge group can damage the turbocharger and cause injuries to persons Have repairs to the cartridge group carried out by an ABB Turbocharging Service Station only NOTICE Quick recommissioning In order to quickly put an engine back into operation after a turbocharger has sustained damage ABB Turbo Systems recommends having a replacement cartridge group available in storage ...

Page 117: ...ing and Installing 11 Fit the turbine casing 51000 back into the gas pipe Attach the cover plate see following section Figure 40 Fitting the cover plate Part number TPS44 TPS48 TPS52 51007 M8 30 Nm M8 30 Nm M10 60 Nm Table 42 Tightening torque 51007 Make sure that the oil connections in the bracket are equipped with gaskets 1 Close the opening in the turbine casing 51000 with the cover plate 01 2 ...

Page 118: ...ems scope of delivery and must be manufactured by the operating company according to the following drawing Material General structural steel in compliance with DIN EN 10025 2 Figure 41 Cover plate drawing Product B1 0 5 B2 B3 B4 0 2 B5 B6 B7 ØD1 0 2 ØD2 R1 M TPS44 62 6 54 110 14 1 144 35 191 5 17 90 M8 TPS48 65 7 60 130 14 1 4 150 35 7 227 7 17 105 M8 TPS52 79 6 80 155 14 1 6 180 39 6 271 7 21 125...

Page 119: ...ng operating materials and supplies Swallowing or inhaling vapours of operating materials and supplies or con tact with them may be harmful to health Do not breathe in these substances and avoid contact with the skin Ensure proper ventilation Observe the information in the material safety data sheet for the operating materials and supplies Wear personal protective equipment PPE according to the ma...

Page 120: ...Service Station and stored separately The turbocharger has been completely removed either as a whole unit or in individual parts For the measures always necessary for preparing the turbocharger parts for mothballing see section Taking out of operation for up to 12 months subsection Preparations for mothballing If the turbocharger remains attached to the engine see section Taking out of operation f...

Page 121: ...ear safety goggles Wear a respiratory mask to protect against dusts Wear safety gloves to protect against mechanical hazards Disposal must be environmentally compatible professional and in compliance with locally applicable regulations The turbocharger consists largely of metal cast iron materials steel nickel steel alloys alu minium and bearing brass Further components are Non metallic materials ...

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Page 123: ...charging Service Station If different model variants are not taken into account in this document contact an ABB Turbocharging Service Station Dispose of placed and unusable parts in an environmentally friendly and professional manner in accordance with the local regulations Dispose of the packaging of new parts in an environmentally friendly and professional manner in accordance with the local reg...

Page 124: ...PS52 H 13 Spare parts Page 94 99 Copyright 2016 ABB All rights reserved HZTL4037_EN Revision A August 2016 13 3 View of turbocharger with part numbers Figure 42 View of turbocharger with part numbers Depending on the specification of the turbocharger ...

Page 125: ... spare part set Gasket 55653 Gasket 56001 Nozzle ring 56005 Lamellar sealing ring 61001 Gas outlet casing 61005 Screw plug 72000 Compressor casing 72011 Hexagon head screw 72012 Fastening strip 72020 V clamp 72041 in customer spare part set Counter sunk screw 72080 Warning plate 79000 Diffuser 81000 Filter silencer 81005 Screw plug 81006 Gasket 81010 in the customer spare part set O ring 82000 Air...

Page 126: ...eration Manual 4 Product description TPS44 H TPS52 H 13 Spare parts Page 96 99 Copyright 2016 ABB All rights reserved HZTL4037_EN Revision A August 2016 Depending on the specification of the turbocharger ...

Page 127: ...on of the turbine 47 Fig 17 Overview of assemblies 62 Fig 18 Removing the gas outlet casing 63 Fig 19 Removing the air inlets 64 Fig 20 Removing the compressor casing 1 2 65 Fig 21 Removing the compressor casing 2 2 66 Fig 22 Press off the casing 67 Fig 23 Do not loosen screw plugs 68 Fig 24 Removing the cartridge group 1 69 Fig 25 Removing cartridge group 2 70 Fig 26 Rotating the cartridge group ...

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Page 129: ...53 Table 20 Malfunctions during operation Charge air pressure too low 53 Table 21 Malfunctions during operation Charge air pressure too high 54 Table 22 Malfunctions during operation Engine performance losses 54 Table 23 Malfunction Turbocharger pumping 55 Table 24 Malfunction Sporadic surge blows 55 Table 25 Malfunctions when stopping Runout noises 56 Table 26 Malfunctions when stopping Runout ti...

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